DNA Owners Club

DNA Owners => Build Threads => Topic started by: Paul79 on April 16, 2013, 10:54:29 PM

Title: Paul's 4thirty Build
Post by: Paul79 on April 16, 2013, 10:54:29 PM
Hi Guys

Let me introduce myself - I'm Paul and I'm about to embark on my first ever kit car build. I've been thinking about it for a while and after spending endless hours reading this forum, looking at other Ferrari replica companies and spending time with Roland and the guys, I've just ordered my DNA F430 Spider kit and should arrive in 8 weeks. Can't wait. Just picked up the donor car on Sunday.  A 2003 face lift model with less than 30k on clock. Gonna build it with my Dad (who's always wanted to do a kit car - he nearly did one 1985 but bottled it) and aiming to finish for summer 2014. (Mind you, given our weather here in the UK these days, that could be November 2014!!  :))

Just like to say massive thank you to everyone who does these build diaries as they are a MASSIVE help to everyone, especially people who are thinking about doing a build and may have second thoughts. I spent hours trawling through these diaries before finally going for it.

Attached in the photo of the donor and I'll try and update with pics as much as I can. I plan to given the number of build hours spent on the car as I go along which should help others gauge how much time it takes.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5844_zpsa528a9ec.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5844_zpsa528a9ec.jpg.html)

All the best

Paul
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on April 16, 2013, 11:36:36 PM
welcome to our great club mate....dont forget to post as many pics as you can, we love em!

if you have any questions about anything at all dont be afraid to ask, many members on here have answered the same question 10 times and still gain pleasure from helping others.

you have made a great choice as this has got to be the most helpful forum I have ever come across.

I too will hope to have mine ready for spring next year so our build swill probably be on the track!

where are you based, just so that anyone nearby can give you more help if you ever need it.

...and most of all ENJOY it, dont rush, it will be ready when its ready!

regards
phil
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on April 17, 2013, 08:59:01 AM
Hi Paul, and welcome.

Phil had pretty much said it all, so I won't repeat.

Looks like a great little vehicle to start with and a good idea to log your hours, something that I never did. However, as a guide I took 10 months from start of strip down to mot and on the road. That was working full-time and caring for my wife also, so these cars do coke together relatively quickly.

You do have to consciously remind yourself to take photos as it's so easy to get carried away in the build. you and your dad will thoroughly enjoy the experience. Post any questions and you should receive several answers within a matter of hours.

Best of luck and as Phil asked, let us know where you are as there may he an owner near by.

Regards

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: tenpin on April 17, 2013, 12:25:42 PM
Welcome, and as others have said, don't worry about posting questions (no matter how daft they may appear).
We all want you to have a great experience building the car and not double guessing about what you should / might have done etc. - we've all been through the build process, some of us more than others, some with practically no experience to begin with  ::)

 - tenpin
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 17, 2013, 01:14:45 PM
Thanks everyone very much for making me feel so welcome - I am based in Essex which I think is where Dangerrous is from. Tomorrow night is the first time I will get to spend on her. I will have to manage my time as I have wife, young family (2 daughters) and work long hours in London! :-) But i'm sure I'll fit the time in!!!
Cheers
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on April 17, 2013, 01:25:47 PM
I'm in Cambridgeshire, Paul, so not too far away  for a run out one day in the summer. 8)

We'll have to sort something when I've got my car all back together again.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 17, 2013, 07:26:44 PM
Beany, why is your car not together?
Title: Re: Paul's 4thirty Build Diary
Post by: sundog on April 17, 2013, 08:37:51 PM
paul79

its becuase hes trying out his homemade electric roof.

btw are you close to completion yet buddy?
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 19, 2013, 08:42:59 PM
Right.......... "LET'S BUILD A FERRARI!"

Build Time: 4 hours

So last night was the first night I got to spend time on her. So this is what I got done. Managed to strip the back end and the front bumper. No problems so far. Just a lot of fiddly poppers to undo.

QUESTION GUYS: on the rear passenger side at the back, what do you do with the pipe that flows above the rear wheel? In the DNA video in think they have got rid of it. Is it a pipe to the air filter?

Cheers
 
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on April 19, 2013, 09:22:12 PM
great progress mate! I love to see the pics of peoples builds....

as for the pipe above the wheel, that will fit into a moulding supplied with the kit which in turn will be bonded behind the upper passenger air intake on the rear end. so you can remove it for now, the large piece of plastic that fits on the end of the pipe and connects to the MR2 air intake can be discarded.

Keep the pics coming!
Title: Re: Paul's 4thirty Build Diary
Post by: NYAL F430 on April 19, 2013, 09:32:07 PM
Welcome, mate keep the pictures coming, the fun about to start ;D
nice to see another build.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 19, 2013, 09:32:33 PM
cheers Phil
the bit that can be discarded  - that's the bit that attaches to the side of the MR2  - not the other end that attaches to the engine at the back. apologies for all the questions...

Paul
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on April 19, 2013, 10:05:51 PM
Hey Paul,

Great progress with the strip down.

My car's not totally in bits, front arch liners, dummy engine and dummy calipers off at the moment. I'm making the dummy engine frame out of metal and sitting it higher as the original fibreglass moulding had to be cut away to fit over the V6.

One of my dummy calipers decided to fall off and I ran over it. As I had to repair it I thought I may as well refurbish all four of them and do a colour change. I've also got a.couple interior trims off to make the fixings for the removable hardtop I'm working on. (Not an electric roof Sunday! Lol.)

Keep the build pics coming. You can sell most of the mr2 parts for a reasonable amount, eBay or www.mr2roc.org.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 19, 2013, 10:21:44 PM
Thanks everyone - next question - in the DNA videos Roland talks about 'etching' the edges of the car where the kit sticks.  What does he mean by that? Also the only other thing that is bothering me at the moment is the amount of holes etc.. that need to be cut out of the GRP panels. For example, at the back of the car where the grill goes.  How on earth to you do it so it is all straight and doesn't look like a botched job?
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on April 19, 2013, 10:30:06 PM
hi Paul,

yes, I meant the bit that connects to the rear quarter panel.

Etching means "roughing up", I asked thesame question when I picked my kit up!!

As for the cut outs, I have just done mine....get yourself an airsaw (if you have a compressor) and a black and decker power file £40 B&Q

check my build thread as I have just done mine and have posted detailed pics! Perfect timing! check here:

http://www.dnaoc.co.uk/index.php/topic,3264.msg22060.html#msg22060 (http://www.dnaoc.co.uk/index.php/topic,3264.msg22060.html#msg22060)

Keep the pics coming AND DONT APOLOGISE  for asking questions mate...I know NOTHING about any of this when I started!

Regards
Phil
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 20, 2013, 08:25:33 AM
Cheers Phil. I don't have a compressor and looking on the web they are at least £200. Can any other saw be used? Surely you can buy a small circular hand saw that runs off electric like the electric file? 
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on April 20, 2013, 12:22:29 PM
Cheapest way to make cut outs is to simply drill a series of holes inside the cut line, join them up using a junior hack saw blade, then file and sand perfectly to the line.

It's not the quickest method, but I still used it n some areas as access with power or air tools is limited. The power file is invaluable if you can get one though. I'm still using mine on loads of jobs, two years after completingmy car.

I use the term completing, loosely, obviously as I can't stop doing things to my car. Lol. ;D

As Phil said, etching is simply roughing the area. A course grit sand paper will do the job, it gives the bonding agent a grippier surface to adhere to, rather than trying to stick to smooth fibreglass gel coat.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: queasy rider on April 20, 2013, 04:45:33 PM
I used the drill and file method for some areas of the engine bay, as Beany says not the quickest but great for accuracy in small areas.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 20, 2013, 08:05:45 PM
Cheers Guys  - will definitely get the power file. And as for the saw, i'll see how it goes. I have a small angle grinder. I'm sure you can replace the disc to be a less agressive one to cut out the GRP?

Dad did some work on her today. Removed both headlights and the right wing. Total build time now 5 hours. I wont get chance to work on her till next Saturday. The car is being built at my Dad's as I simply don't have the space (my garage is too short and is currently a utility room & a home gym!) but when she is finally built I'll be extending the garage to fit her in (now that's commitment eh?   ;) ) Will have to sell that dusty gym equipment!



Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on April 20, 2013, 09:18:04 PM
Paul, hi.
Great to see another build. As you probably know I'm currently building a 430 Spyder and glad to help with anything that you need to know.
Do not throw the MR2 bits away, you can get some good money for them on that auction site :)
Keep the good work up.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 21, 2013, 06:13:51 AM
Yep, cheer Rudy. Been photographing each piece as it comes off the car ready for listing. Saw your build diary yesterday. Looks great. Where did that centre console comes from? Really like that.
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on April 21, 2013, 10:38:52 AM
Looking good Paul and if you need any advice on prep or paint drop me a mail

Keep the pics coming :)
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on April 21, 2013, 06:08:45 PM
Hi Paul,
I bought it from a guy in Malaysia on the bay.
Thanks
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 22, 2013, 10:24:45 PM
Phil, been reading your thread in great detail - very good and has helped answer loads of questions I had. A more general question i have is the order in which to do things. My plan is as follows:

1) Kit wont be ready to pick up for another 6 weeks i reckon, so get car prepared as much as possible
2) when kit arrives i thought about doing the suspension and wheel spacers first to get that done
3) then fit the body work
4) then send to the paint shop

is this the right way to do things? does it matter? various build threads show things in a different orders.
also i haven't bothered getting the fake brake discs yet. can they be added after the spacers have been put on? or is it too late by then? i figured i wont really need them till the very end of the build. also on the spacers - do most people fit them and then take them off for the paint shop so the car has old wheels on for the paint shop? i guess this is just to stop the paint shop accidentially spraying the big alloys?

cheers guys

Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on April 23, 2013, 11:54:04 AM
Hey Paul,

Suspension can be done first. The main thing is to get the front inner wheel arches bashed in before the bodywork goes on, so is probably better to sort while car is in bare chassis. I had to increase my wheel clearance a little more after I had bonded on front clip and doors. A very precarious undertaking with a sledge hammer.   :-\ so make sure you have about half inch from 19" tyre on full lock.

No problem fitting dummy brakes later as discs fit between wheel and spacer and caliper mounts attach to the mr2 caliper bolts.

I removed wheels and spacers and sent my car to paint on mr2 wheels, merely to protect the 19's. The thing to bare in mind is the car is exceptionally low after the suspension mods and you sit it back on 15" rims, so there may be some difficulty getting the car on a trailer. I had to use wooden blocks, firstly under the front wheels to clear the front bumper from the ramps, then under the rear wheels to stop the sills grinding on top of ramps.

Best to transport car with front bumper removed. Hope that helps.

Beany ;D

Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on April 23, 2013, 02:06:25 PM
Paul,

I think Beany answered all your questions, as for which order to do things......I myself am more mechanically minded than bodywork minded, so I set about getting all the mechanical stuff done on the car that I can. The hardest job I found was hammering in the wheel arch as Beany says!, you need to have your front suspension and wheel spacers fitted so you can test fit the wheel and check clearance, I removed the hub to hammer mine in as I kept catching it with the hammer, also, get youself some 50mm long wheel studs (see my thread), as trying to get the front wheel on and off using bolts is a nightmare!

I am very scared about fitting the body, as I have no experience in that field, I am just really going to dry fit the whole car first to make sure its all OK, as I have no idea on how much you dont have to worry about that can be fixed by the body shop!

download the build videos and get the car stripped down and cut/folded ready for your delivery!!

I will keep trying to record the detail in what I am doing for people like yourself, cos I know some of the things other builders take for granted are like magic to people like us!!

Best of all, dont rush it and enjoy it.....if it doesnt seem to be working, then give up for that day or try something else, another day will see the problem solved....and ask as many questions as you have to...we are all here to help.

good luck
Phil
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 23, 2013, 04:01:51 PM
excellent advice as always guys. thanks so much. Dad is working on her a bit today so might have some photos later to show you..builder is coming round tongiht to see if we can extend the garage! fingers crossed it is possible, other wise i could be in trouble!  :-\ roll on home time!
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on April 23, 2013, 04:19:24 PM
make sure you post LOADS of pics! we love 'em!!

Also, as I have just found out, check the WIDTH of your garage door, as when the body and mirrors are fitted, its VERY wide!!
It wont fit through mine with the mirrors on, so I will removable mirrors or better still, folding mirrors.

I may have a go at making the supplied ones fold or maybe get hold of real ones and make them fit!....dont know yet...something I have a long time yet to think about....
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 23, 2013, 04:26:42 PM
I have been told by Rudy that including the wing mirrors it is 78 inches wide. DNA said something similar (but i can't remember right now). I just have in my mind that if the garage door is 80 inches wide I should be ok.. What numbers did you have Phil?
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 23, 2013, 09:04:12 PM
Sorry Phil - only 1 photo tonight. Dad spent an hour on her today and now the front end is completely stripped. Good news on the garage extension - it is doable. Hooray! Won't need to do it for a bit though. Maybe a year! LOL!
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on April 24, 2013, 08:59:04 AM
you can remove the frunk as well mate as you will probably find things a bit rusty under there....I cleaned it all up and hammerited it all.
 
Also, you wont need the frunk lid anymore so sell that.

Another tip is, as you wont require the spare wheel anymore, that leaves the alarm in the frunk sticking up on its own, what I have done is mounted it underneath the frunk and out of the way, you now have the whole frunk as a "boot"!
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on April 24, 2013, 09:42:35 AM
Hi Paul great seeing another build good idea putting the hours spent in thread nice that your dads helping. saving up for a kit myself ,be nice to build with my 26 year old son .keep up the great work summer 2014 just around the corner ,good luck with everything .with all the skill and help on this forum should be a fun build and something that you and dad will enjoy together
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 24, 2013, 10:59:50 AM
Cheers Phil, will defintiely put that on the to do list. Maybe I could line the 'boot' with a lovely leopard skin fur print!!  :-\ .........err...or maybe not!

Thanks ghall164. I thought that logging hours would be more useful than just months as people work at there own pace and at different times. Then hopefully other builders like yourself can really get a sense of what work is involved and how long so you can budget. I have a nerdy spreadsheet up and running detailing everything we are doing. How long before you can get your kit and start your build? Will you be doing a F430?

Question for everyone: I'm getting the DNA F430 comprenhensive kit, (which is very comprenehsnive!  :) )  - however what fixings parts (screw/bolts etc..) are included in the kit? Things like tech screws I guess are not...

Can anyone possibly tell me the extra parts i need to buy and possibly the sizes? I've bought a selection of M4-8 nuts and bolts to get me started

I have a small list going here:

>Bicycle brakes cables x 2 for doors
>Solderless Nipples x2 for doors

Cheers as always guys.....

Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on April 24, 2013, 11:10:13 AM
from top of my head.....

you will need a 19 deep cranked ring spanner to fit the front spacers on with...see my build thread
lots of small nuts and bolts to assemble the fake disks, see mine or beanys build thread
50mm wheel studs for the front spacers to convert to nuts instead of bolts
20 new wheel nuts - need to be slimmer to fit the new wheels, again see my thread
hammerite paint for suspension parts - if you want it to look nice!
all ferrari decals etc...for fake calipers and the whole car
dial backs for your speedo to look like ferrari
push button start for steering

thats all i can think of at the mo.....
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on April 24, 2013, 04:11:01 PM
You will also need the mondeo fuel filler cap.
Suggest new discs and pads, full engine service.
New glass if you do not want to Toyota script on them.
Change windscreen rubber to look like the original Ferrari rubber.
Blead nipples, etc. for calipers.
Horn push button
Hope this helps.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 24, 2013, 04:50:32 PM
Cheers Guys
Will have a good look at brakes and discs when i get the wheels off. Good point about the stamped glass. Will have a look on saturday. Phil, where did you get your wheel studs from? What material do they need to be? Stainless steel is not the way to go i read somewhere. can you remeber the width of the studs?
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on April 24, 2013, 05:55:14 PM
these were the item myself and Rudy bought...

http://www.ebay.co.uk/itm/370476921452?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649 (http://www.ebay.co.uk/itm/370476921452?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649)

they are:

Vauxhall Conversion Wheel Stud M12x1.5mm 50mm Long

and the description states:

M12x1.5mm Pitch Theadwith total lengh of 50mm Long High Tensile Steel

so not stainless steel as they would probably snap off!

I have also ordered 2 standard M12 x 1.5mm pitch nuts so that I can lock them together on the thread and then use them to tighten the thread into the spacer, as it keeps coming out with the wheel nut!
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on April 24, 2013, 05:56:13 PM
hey Rudy, do you have the info on the windscreen rubber you used?
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on April 24, 2013, 06:34:01 PM
Probably be a year away need to do some saving and convince the better half lol can't make mind up as to which kit love the dn8 but will miss my TT soft top now if they were to build a dn8 spider that whould be an easy decision haha loved beanys yellow and black striped f430 and beemermans white one best keep saving keep up the hard work and there's nothing wrong with keeping track with a spreadsheet just don't let the missis see what you've spent haha
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on April 24, 2013, 07:13:31 PM
Phil,
If you pm Beemaman he will be able to advise as he is doing mine.
Well I guess you all figured that out by now.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 24, 2013, 07:56:40 PM
Phil, do I need those wheel studs for the front and back wheels or just fronts?
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on April 24, 2013, 09:14:45 PM
just fronts, the back spacers have them in...not sure why dna dont supply them in the front as well.....
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on April 24, 2013, 10:46:17 PM
make sure you post LOADS of pics! we love 'em!!

Also, as I have just found out, check the WIDTH of your garage door, as when the body and mirrors are fitted, its VERY wide!!
It wont fit through mine with the mirrors on, so I will removable mirrors or better still, folding mirrors.

I may have a go at making the supplied ones fold or maybe get hold of real ones and make them fit!....dont know yet...something I have a long time yet to think about....
            I seem to recall enzo mirrors advertised on  madmechanics that showed them dismantled, give you a good idea how to adapt yours, you just need to find the thread ;D
MADMAN
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on April 25, 2013, 07:59:05 AM
Hi phil

If you want some windscreen trim the same as in mine I can supply you some and send it up to you.

Or I can put the screen back in  with new trim after I've painted car for you (wink wink) :) :)

Beemaman
Title: Re: Paul's 4thirty Build Diary
Post by: kalifornia on April 25, 2013, 09:40:38 AM
I still have a couple of ferrari dial backs if anyone is interested ?
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 25, 2013, 10:01:40 AM
kalsingh1  - i could be interested. i'll PM you.. cheers
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 25, 2013, 12:01:18 PM
Need Help Guys. Dad is trying to take the door trim's off  - he's undone all screws/poppers around the edge, and the screw in the interior door handle housing, but says it still won't come off. It still seems attached around the interior door handle area - any ideas? does something need to slide off? Attached is a photo where he thinks it is still attached somehow

Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on April 25, 2013, 04:18:42 PM
pm me your email and I will send you a pdf on how to remove it
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 25, 2013, 04:24:08 PM
done Phil, cheers
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 27, 2013, 06:12:47 PM
Evening Guys

Spent a good 7 hours on her today. Total build time now 14 hours. This is what I got done: Removed air intake pipe, door trims, wing mirros, sills, interior moudings behind seat, marked and cut doors, marked and cut small pieces near roof, folded rear seams, folded seams for door cards, lowered windscreen washer drive, trimmed bumper bars.

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 27, 2013, 06:21:36 PM
More pictures....

QUESTIONS: do I have the lower both windscreen washer drives? I have only done the outside one so far...plus on the rear quarter seam folds, do I also need to fold the seam right to the end of the car? As I have circled. Or is it just as I have done?
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on April 27, 2013, 06:31:15 PM
Looking good buddy

I can't remember the folds exactly I'm sure someone can advise on this.

You will soon be ready to dry fit and cut all the kit sections out :)

Keep the pics coming buddy
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on April 27, 2013, 06:33:16 PM
Guess there's no going back now lol coming along great love to see new builds very jealous well done
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 27, 2013, 06:34:37 PM
Finally - bit of a downer, when cutting the passenger door outer skin, I went too far through on part of it and cut right through the internal door skin in places. I have added a photo showing what I have done. Thing is, is this really bad? I see that the part I have cut, it actually comes to an end about 1cm further down anyway. Could I just leave it, or maybe just stick some metal filler/bonding agent to seal it back together again. I haven't jeopardized the structure of the door have I?


Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on April 27, 2013, 06:41:12 PM
Do you have a welder ?? If not and your worried you could bond the skin back together and either screw it or pop rivet it too along seem.I'm sure it won't jeapordise the structural side too much.
Title: Re: Paul's 4thirty Build Diary
Post by: Darren on April 27, 2013, 07:18:53 PM
Careful when cutting the doors, keep what you've cut as the new doorskin requires two bits to hang so it can be accurately fitted, I'll post an earlier video from youtube to show the doorskin fitting in detail
D


http://www.youtube.com/watch?v=ud3dd3yHx0k&feature=youtu.be

Posted originally 18:00hrs
Title: Re: Paul's 4thirty Build Diary
Post by: mantav8 on April 27, 2013, 08:28:22 PM
Careful when cutting the doors, keep what you've cut as the new doorskin requires two bits to hang so it can be accurately fitted, I'll post an earlier video from youtube to show the doorskin fitting in detail
D


http://www.youtube.com/watch?v=ud3dd3yHx0k&feature=youtu.be

Posted originally 18:00hrs

Excellent video D!-will help lots of peeps I reckon. ;)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 27, 2013, 08:35:35 PM
Yep, thanks D. Will be referring to it when I get my kit and start fitting it. Especially like the point made about people leaning on the window. Cheers
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 06, 2013, 05:13:21 PM
Spent 4 hours on her total. Total Build time so far: 20 hours

Jobs done since last update: Etched all doors/A pillars/rear parts, shortened door check straps, removed washer bottle, removed boot and treated rust underneath & primed, removed all 4 wheels and sprayed WD40 on all suspension parts ready for fitting, filled holes in boot. Re-positioned alarm to be attached to outside of boot.

Dad will prime all the etched bits this week, so now just waiting for the kit to be ready. Had a good look at the suspension and soaked all the nasty rusty bolts.  Checked the condition of all 4 discs and pads. Loads of meat left on pads and discs so all fine. I also filled in those door cuts I was worried about with metal epoxy. Should be fine. Next to load up all MR2 parts and try and flog them.



Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on May 06, 2013, 05:18:10 PM
looking good mate! keep those pics coming
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on May 06, 2013, 06:08:00 PM
Well done Paul coming along nicely  ::)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 06, 2013, 07:18:48 PM
Cheers guys for comments. Question on cutting the fuel pipe. How on earth did you get to it you cut it? Looks too tight to get an angle grinder in there. Is the only way a single blade metal saw?
Title: Re: Paul's 4thirty Build Diary
Post by: mantav8 on May 06, 2013, 07:20:37 PM
Cheers guys for comments. Question on cutting the fuel pipe. How on earth did you get to it you cut it? Looks too tight to get an angle grinder in there. Is the only way a single blade metal saw?
Yup!-or a chain cutter....... ;)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on May 06, 2013, 08:34:01 PM
you dont need to cut it to remove the filler pipe and breather, check my thread from here:

http://www.dnaoc.co.uk/index.php/topic,3264.msg22057.html#msg22057 (http://www.dnaoc.co.uk/index.php/topic,3264.msg22057.html#msg22057)

the main filler joins at the petrol tank under the car, just drop one of the nappies near the back wheel to see it, the breather joins just pased the bracket you can see in my first pic.

I then cut a couple of inches off the end of the breather to insert into the new blue breather, this will then reconnect back to the original fitting below the bracket.

The new large black pipe will fit straight over the existing connection under the car near the tank.

P.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 06, 2013, 08:39:20 PM
nappies?  :o
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on May 06, 2013, 09:30:58 PM
the plastic shields under the car.....
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 06, 2013, 09:36:19 PM
ah i see. OK thanks very much dude, i will have a look under there next time I'm over. got any more stuff done on your car lately? cheers
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on May 06, 2013, 11:37:17 PM
Ah, all these photos bring back memories.

Seems like a lifetime ago now. Maybe that's a sign for something else? :P

Keep up the great posts Paul.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on May 06, 2013, 11:45:21 PM
I had a little go tonight...only 1 hour or so, so I messed with a front and rear fake caliper.....the front needed some bending and adjustment of the holding plate to get it to sit right, also, with my wheels, I had to put three nuts between the fake disk outer plate and inner plate ( as confirmed by Roland on Sunday! ) and take a little off the fake caliper edge, otherwise it caught on the wheel, sorted this now!

Rear one was easy, it just fit!

Good talk with Roland on Sunday, answered all my questions I had about the build, laid my mind at rest really...cant wait to get more time on her....or well, suppose I better get to bed to get up tomorrow to catch the plane to Egypt  ;D 8) ;D

I hope they have free wifi on the hotel...cant miss my fix of dna forum updates!!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 08, 2013, 09:30:54 PM
Next question guys: paint. Does anyone know approx how many litres of paint is needed to paint the 4thirty?
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on May 08, 2013, 09:42:00 PM
Depends if your using 2-pack or basecoat ?

If 2k then get a 5ltr tin as you will need at least 3-3.5ltrs and always good to have some spare just incase.

If basecoat and laquer you will need about the same in basecoat and a good quality gallon of laquer.

There's plenty of good but not too expensive laquers out there

Also there's polyester and primers if doing it yourself ??
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 08, 2013, 09:49:25 PM
cheers Beemaman, but 2 pack or basecoat? Sorry I don't know what that is.  :-[
I will be getting my local paint shop to do it, I was just wondering how much paint was needed and ether it is cheaper to supply the shop the paint myself. Or just best to leave it all to them
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on May 08, 2013, 09:57:18 PM
Hi buddy

2-pack is a straight colour so if your having red/white/black/yellow you can use this.

Basecoat is any colour you like followed by a clear top coat (laquer) you can also have the above colour in a basecoat and laquer.maybe best talk to a bodyshop about what you want and require ??

We're you based ??
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 08, 2013, 10:09:42 PM
Ah I see. I thought it was just primer, then paint and then lacquer. I just want it Rosso red. Nothing flash or complicated. Just nice and red. I'm based in Essex.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 09, 2013, 11:25:29 AM
my paint shop says it has to be 2-pack paint, otherwise it will fade. certainly don't want that
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on May 09, 2013, 12:29:34 PM
Beemaman is one of the bodyshop experts on this forum Paul.
His advise is well worth listening to as he is a perfectionist.
Look at his car on his build and you see what I mean.
I have seen his work and it stands out by a mile.
2K for solid colours is the way to go.
Make sure your bodyshop uses a premium brand of paint otherwise it will reflect in the finish.
You get what you pay for, like anything else.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 09, 2013, 03:58:57 PM
Cheers Rudy/Beemaman, yes I am pretty sure this paint shop is fine. They've been doing it 35 years, and the guy even knew the paint colour name/code before Dad's told him.
Title: Re: Paul's 4thirty Build Diary
Post by: Darren on May 09, 2013, 07:28:56 PM
ICI basecoat and good quality laquer won't fade, old paints used too but the pigments in these basecoats are much better nowadays.

Laquering the car will give a rich vibrant deep colour, basecoat and laquer just tends to be a little more expensive.
D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 20, 2013, 10:15:37 PM
My new best friend!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on May 20, 2013, 10:27:18 PM
and mine too!!
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on May 20, 2013, 11:55:16 PM
Still use mine for all sorts of jobs now, two years after completing my car, although i'm not sure it will ever be complete.

Been discussing re-trimming the seats with the wife, so that may be the next spend.

You can't go wrong with the power file, it's great!

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 21, 2013, 11:05:51 PM
Guys - question on pre cats. I read build threads such as beany's and phil's and u remove the pre cats. I have a face lift model car. Do I/should I still do this? Does it increase engine torque/noise? I guess there no issues with the mot emissions. Was unsure of whether I should do it. Is it easy to do? Anything to watch out for? Cheers
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on May 21, 2013, 11:16:17 PM
Hey mate, yes it's an easy enough job. I think I detailed the steps fairly well early in my build.

The main reason for doing this little mod is there has been issues with a lot of cars where the pre-cat material has started to degrade and small fragments have ended up working their way into and killing the engine.

The main caution is to make sure that you remove all traces of the cat material, it is fairly brittle and breaks away easily. Be sure to use an airline to blast plenty of air through the manifold to remove any remaining fragments and dust.

I can't say I noticed any difference in sound or performance (Until I fitted the V6 that is ;D) I removed the pre-cats primarily to protect my old engine. The other alternative is to fit a stainless steel manifold. Either of these could cause emissions to fail on a cold engine, as the pre-cats were designed for the American market to reduce emissions on start-up. Once the engine is up to temp there should be no issues with emissions.

Hope that helps.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 21, 2013, 11:27:24 PM
Cheers Beany. Very helpful as always. Looks like I know what my next job is!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 30, 2013, 09:47:41 AM
questions guys - will the headlights for a 2003 year MR2 (facelift model) fit a 2000 year model (pre-facelift). thanks
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on May 30, 2013, 10:01:59 AM
Paul,
I think they do as a lot of guys buy these lights to upgrade the MR2.
Worth putting a question on the MR2 owners forum.
I sold mine to a guy upgrading.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 30, 2013, 11:07:48 AM
cheers Rudy, will do
Title: Re: Paul's 4thirty Build Diary
Post by: Nik the Greek on May 31, 2013, 09:08:38 AM
Hey Paul.I just read yours.Very nice so far.Cann't wait to see it with the panels.
I'm jealous. :) :) :)
Title: Re: Paul's 4thirty Build Diary
Post by: Darren on June 02, 2013, 09:31:31 AM
petrol cap flap ready to pick up or have delivered, I'm only in Essex.
D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 02, 2013, 09:41:16 PM
Cheers D, I'll PM you
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 02, 2013, 09:56:48 PM
well, we are nearly there... this time next week i will be a full DNA owner. As promised DNA delivered the kit within 8 weeks. awesome. No real updates on the actual car build (or photos  - sorry) but spent 5 hours tidying up the car port and garage ready to put the kit in and generally getting really organised for the build. absolutely knackered now but very happy now with how everything is. been reading the build diaries to and from work as well, so really starting to feel comfortable with things and how i am going to do the build. picking kit up on friday with penty of questions at the ready!!  i wonder if Brian will be back from India? ;D
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on June 02, 2013, 10:56:54 PM
Good luck for Friday Paul let the transformation begin exciting times for you and dad pal
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on June 03, 2013, 09:22:50 AM
yea...good luck Paul, above all have fun, if it starts to get you down, walk away and come back later to see it in a different light.

As before, fire any questions to the forum no matter how trivial, someone will answer and answer nicely, not like on mad mechanics, when people ask questions on that forum I've noticed someone ALWAYS replies with "you should try the search feature instead of asking a question that's already been answered"....I think that's terrible, some people don't really know how to search and also what words to use (like me sometimes!), and if you ask it in your build thread, then the answer is in the right place for someone else who is reading your thread and hits the same issue!!

cant wait to see you pics, take loads and get them on here for us all to see!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 03, 2013, 09:41:25 AM
cheers Phil, will be re-reading your build diary over the next few days as well!!!
Paul
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on June 03, 2013, 10:25:02 AM
Hey Paul,

I take it you don't drive to work? Lol.

Hope everything goes smooth with your collection, it's amazing to pick up everything you need to make your dream car.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 03, 2013, 11:41:57 AM
haha, well not all the way! i have a 10 mile drive to station and back everyday, but there is no way i'll be leaving the finished car in the station car park everyday! mind you, there are some tasty motors in the car park!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on June 03, 2013, 01:07:27 PM
I too work in london mate and spent many an hour on the train going through the build threads and the build videos!!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 06, 2013, 10:05:58 PM
so the time has nearly arrived.... tomorrow is DNA-Day! really looking forward to the day trip. beats sitting at a desk staring at screens all day! Dad is in charge of the digital camera and i'm gonna film it all as well. this should help me loads when i forget something and i can just watch the film back. should also be helpful to others in years to come. might even get a glimpse of Brian's nice tan from India! should be with you between 11 and 12 DNA. depends how fast the luton goes on the M6!!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on June 06, 2013, 10:13:57 PM
Video or voice recording is a great idea as there is a lot of information passed regarding the various components.

Hope all goes well.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on June 06, 2013, 10:41:22 PM
Video or voice recording is a great idea as there is a lot of information passed regarding the various components.

Hope all goes well.

Beany ;D
Dont forget your interpreter, it,s Brumland at it,s best ;D
take a few old blankets or bubblewrap for packing, and enjoy
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 06, 2013, 11:14:02 PM
No probs madman. I lived in Birmingham for 3 years so I should get by!  :D. Cheers for advice on blankets.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 08, 2013, 12:11:42 AM
well.. what a day! absolutely knackered! spent 8 hours on the road today, including 3 hours in traffic jams, but i now have the whole kit thanks to the good chaps at DNA. was a great day out and Roland and Brian were great (also the other guy whose name i missed - cheers mate. especially for loading everything on the van!) thanks guys for the experience. cheers Roland for the the ice creams and I hope you liked the doughnuts. shot 1.5 hours of video (alot of it was Brian's tan!  ;D) all unloaded and most of it at Dad's. will have a day off tomorrow and maybe make a start sunday on suspension/exhaust. i just can't believe how many traffic jams i was in today. especially as it was one of the warmest days of the year and i was stuck in a van with no air con.
cheers
Paul  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on June 08, 2013, 03:12:23 AM
Great news Paul,

Now the work really begins, get used to being dusty, lol.

I haven't forgotten those measurements, i'll sort it this week and pm you.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 08, 2013, 06:33:59 AM
Cheers Beany
Paul
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on June 08, 2013, 11:06:12 AM
Paul
I expect those around you wondered why you were grining while you were sitting in a traffic jam.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 08, 2013, 10:06:59 PM
Cheers Mick
Thanks again for bringing the Furrari in that Friday in April when I came up over 2 months ago. (not sure if you remember me). At that time I was still undecided as to whether to go for a 5cudo or a 4thity. In the end, it was my wife who said: "If you must do this kit car thing, at least build me a convertible!" So there you go. I've to you to blame!  ;D. Spending a whole day on the car tomorrow. Cleaned my new wheels today. Love em. Most of the kit is at my Dad's house, but I have a few bits at mine. Today I converted a wallpaper table into a Ferrari red felt covered work station where I do my 'delicate' work (Headlights et al). My garage used to be a gym with 4 pieces of gym equipment which are now being sold (hardly used - seemed like a good idea at the time  ;D) to make way for my car work and eventually the car (I lost the shed a while back to all the gardening stuff - I am married to a lovely looking Charlie Dimmock).  In the mean time I will do as many things as I can in the garage. All the best.
Paul
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on June 09, 2013, 08:53:41 AM
No problems Paul.  Of course I remember the visit, but probably not the face. (It's an age thing).
I regard it a pleasure, privilege and honour to show the Furrari off to people who are interested.
Welcome to the DNA owners family.
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on June 09, 2013, 08:59:45 AM
Paul. Just read your post on June 3rd.
The station is one place I won't take the Furrari cos as the rattlers to through they gring a bit of steel off the rails.  This dust eats into the paint and is very hard to remove.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 09, 2013, 10:08:43 PM
Had a full day on car at last today  ;D ;D ;D

Total build time: 28 hours

Changed rear springs, took off old exhuast box and put on DNA rear silencer, striped both front suspension and banged back drivers side arch. Sorry no, photo of new exhaust box. but started her up and sounded great. Nice and loud. Thought about doing rest of exhaust but tbh.. i think the rest would be best done with the back clip on so we can see exactly what goes where and how it lines up. Need to replace on of the suspension bolts (the long one that goes through the suspension member brace and then through the lower suspension arm, through the ball joint and into the body. It came out of the car alright but just kept spinning and spinning, but just couldn't get it out of the original ball joint without a lot force. think the thread is a but dodgy so will replace).

i was banging back the arch and i got a split in the black thin lining. Has this happened to anyone before? is it a problem? i think i have banged the arched back as far as it will go.  can anyone see whether i have done enough? Please see photo 7 with the black circle.

Next time to pay Wednesday night. will do some less physical work such as brackets and tech screws etc.. I'm going to ache tomorrow!!!!  :-[
Title: Re: Paul's 4thirty Build Diary
Post by: Nik the Greek on June 09, 2013, 10:48:11 PM
Nice work.And nice wheels.
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on June 11, 2013, 11:12:50 AM
great work Paul!!

I remember banging back my wheel arch I was physically knackered!!

Mine didnt split though, as I kept banging it back, refitting the wheel and banging a bit more until it cleared....
This was fine on the jacks, I then put the car on the ground, applied full lock and it is still catching  :(

I will have to remove the wheel and hammer a bit more yet.....thats for another day!!

Regards
Phil
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 11, 2013, 11:46:11 AM
Roland says the split is not a problem as it is doubled skinned, when i am all happy with it i will stick it back and then underseal it all. I'm not going to bang it back anymore. i want to get suspension on and fit wheels and see exactly where it is rubbing. Then i can be more selective with my banging! I've banged it back alot so hopefully not much more to do. will do other arch tomorrow night and move onto something a bit less strenuous like fitting brackets! 
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on June 11, 2013, 04:06:58 PM
Looking good looks like a great way of relieving the stress levels bet you enjoyed the sound of the new exhaust  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 11, 2013, 09:10:26 PM
yes ghall, i videoed the sound of the exhaust before and after. it didn't come out great but in realilty i loved the sound. quick update: Dad cut out holes for roll bar today. i'm going over after work tomorrow for 3 hours.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 13, 2013, 10:33:01 PM
Guys, what thread lock stuff do people use for the wheel spacers etc...? I see you can get certain types. Medium to high strength. I guess it can't be too strong as you need to undo them sometime ( to change the brake discs etc...
Cheers
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 16, 2013, 08:46:39 PM
Update from Wednesday night: total build time: 32 Hours

Banged back passenger arch, fitted front bumper brackets, trial-fitted roll bar bracket and roll bar carrier, prepared front wheels hubs for spacers, cut out door holes, ground back door brackets, labelled up all front light wires

***Be aware new builders*** you need to pre-drill all holes to put bumper brackets on! Teck screws certainly don't drill through this hardened steel. Also, when i picked my kit up the other day Brain said to grind away the top of the door hinge brackets (see photos) as he found on the india build that they stuck out too far. grind down nearly to the first row of holes. I may need to bend the end down as well but will only know when i fit the door skin. you can't have them touching the inside of the door skin as it will cause a bump and ruin the door skin over time

also cut out door handle and access panel holes. need a bit of a tidy up but will do that later.

Roll bar bracket fitted but nothing fixed permanently. will wait till doing all of that part later on to attach. it seem's the actual the roll bar hoops need to be screwed to the bracket before the bracket is actually fixed to the car. unless i am mistaken.

also i needed to check whether i would need to roll the car back slightly when the front clip was on, so i tried it on to see! wow, what a transformation! looks awesome. plently to do before, mind! next jobs - plan on getting all front suspension put back together starting thursday night and all day sunday and getting front and rear spacers on as well. i don't plan to change back to the mr2 wheels again (for painting) so i am just going for it with the spacers. for most of the build afterwards the car will be on axel stands. 

marked out rear light holes for dad to possibly cut out during the week.

***Guys*** - question on thread lock a) what version did you use? loctite medium strength or high strength? surely it can't be high strength as you need to undo do them again to change discs etc.. and b) does anyone thread lock the suspension parts as well?

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 16, 2013, 08:52:44 PM
....and as it was father's day today - here is a picture of my little ratbags sitting in the car. this was the first time they had seen it all. they couldn't believe it didn't have any front wheels! is it a boat they asked?  ;D


Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on June 16, 2013, 09:03:41 PM
good update mate!

On the door handle plate, I didnt have to cut mine at all, so I would maybe tek screw it on with one screw and then test fit the door skin to see where it lines up....too much off the bracket will mean that the door handle hinge wont be in line with the cut out for the door handle in the door skin!!
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on June 16, 2013, 09:04:12 PM
Nice work mate. Keep it up and enjoy.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 16, 2013, 09:27:30 PM
Yep, will do Phil. Cheers.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on June 16, 2013, 09:56:13 PM
cover all your wiring labels with a plastic bag or similar, then they wont get coverd in paint etc. then you will still be able to read them when reassembling
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 16, 2013, 10:06:26 PM
Cheers for the tip MADMAN.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 22, 2013, 03:37:06 PM
Guys, does anyone have the 430 roof fitting guide to hand? I just want to see what is involved. I guess you retain the orignal MR2 roof frame and recover it...will have a build update tomorrow night. Cheers,  Paul
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on June 22, 2013, 04:54:41 PM
Guys, does anyone have the 430 roof fitting guide to hand? I just want to see what is involved. I guess you retain the orignal MR2 roof frame and recover it...will have a build update tomorrow night. Cheers,  Paul
            I have, I think it,s in Aladins cave ;D I,ll email it to you
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: mantav8 on June 22, 2013, 06:54:02 PM
Guys, does anyone have the 430 roof fitting guide to hand? I just want to see what is involved. I guess you retain the orignal MR2 roof frame and recover it...will have a build update tomorrow night. Cheers,  Paul

Don't know if it helps mate but my build thread shows how I fitted the roof,have fun! lol!
 ;)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 22, 2013, 07:46:28 PM
cheers Guys, great help as always
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 22, 2013, 09:15:52 PM
Dad's been working during the week cutting out the holes for the rear lights. He finally finished today...

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130622RearLightsTrialFitted_zps9d194c52.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130622RearLightsTrialFitted_zps9d194c52.jpg.html)

and from the side...

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130622RearLightsTrialFitted2_zpsa0c68461.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130622RearLightsTrialFitted2_zpsa0c68461.jpg.html)

Also the over cuts I had made when cutting the door tops have been spot welded. Dad says they are nice and solid with no movement.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130622DoorSpotWeld_zps7fcec915.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130622DoorSpotWeld_zps7fcec915.jpg.html)

I'm going over for a full day tomorrow
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on June 22, 2013, 11:14:32 PM
This is a great bonding time for father and son, Enjoy working together it is priceless
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: tenpin on June 23, 2013, 01:06:13 PM
This is a great bonding time for father and son, Enjoy working together it is priceless
MADMAN 8)


Surely that comes later and involves Sikaflex?  ;D  ::)

 - tenpin
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on June 23, 2013, 01:38:05 PM
Great work and keep it up.
Like Madman said, enjoy the experience, its priceless. :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 23, 2013, 08:42:48 PM
Right, now that I have washed out all the dust from my hair, time for an update: Total Build Time: 46 Hours

Thursday night I started to refit back all the front suspension. Thread locked the new A-arms and put back shock absorber. Just waiting on the ball joints to fully fit it all back.  Did this both to drivers and passenger sides. I also threadlocked the rear suspension parts I reassembled as well.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130623DriverSuspenionPartFitted_zps3af925c2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130623DriverSuspenionPartFitted_zps3af925c2.jpg.html)

Next was door skins. Trimmed backed the passenger door first. Takes time, but managed to get it to fit quite nicely me-thinks.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130623PassDoorSkin2_zps1cc6b9cf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130623PassDoorSkin2_zps1cc6b9cf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130623PassDoorSkin3_zpse5f34b09.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130623PassDoorSkin3_zpse5f34b09.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130623PassDoorSkin4_zpsee082a28.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130623PassDoorSkin4_zpsee082a28.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130623PassDoorSkin5_zps9be95a6d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130623PassDoorSkin5_zps9be95a6d.jpg.html)

Next Dad put a picture up on the rafter to show everyone who comes round what we are aiming to get to!!!  ;D See circle in picture below!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130623TheEndResult_zps7669a12e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130623TheEndResult_zps7669a12e.jpg.html)

Next the door handle hinge. Now, on the passenger side I had trouble here getting it to sit far enough back and high enough. I dont know whether I have the wrong hinges but I did adjust the hinge to sit as far back, but still no good. In the end I decided to cut the bracket and move it backwards and pack it out to raise it up a bit. Not pretty but it seems to work and the main thing is there is no touching of the bracket on the inside of the door panel. You don't want any touching as it will cause a bump on the outside of the door panel and look poo.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130623PassDoorHandleHinge1_zpsb4940f22.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130623PassDoorHandleHinge1_zpsb4940f22.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130623PassDoorHandleHinge2_zps8aa714c4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130623PassDoorHandleHinge2_zps8aa714c4.jpg.html)

Added the twisted bracket and tired with the bicycle cable and seems to work. Will not bother bonding the door handle until the dry fit is complete, or even the door are bonded. Tech screws the doors to the body to hold them in place for now.

Final passenger door photos:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130623PassDoorFinal1_zpsbf6a69c2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130623PassDoorFinal1_zpsbf6a69c2.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130623PassDoorFinal3_zps1bc8af9b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130623PassDoorFinal3_zps1bc8af9b.jpg.html)

Repeated the same on drivers door. This time the opposite. Hinge sitting too high through hole, so had to lower it by packing out with spacers on the bit where the hinge attaches to the bracket (sorry no photos). I couldn't even adjust the hinge back as screw was just too tight and head snapped off, so cut and moved bracket back again to get right. Still sits a bit too high, but the handle can be reduced in depth to accommodate and sit flush.

Final Drivers door photos:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130623DriversDoorFinal1_zpsbeafe0e2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130623DriversDoorFinal1_zpsbeafe0e2.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130623DriverDoorFinal2_zps49b72154.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130623DriverDoorFinal2_zps49b72154.jpg.html)

Took the front bumper home to cut out grill holes next weekend. Until next time.... ;D


Title: Re: Paul's 4thirty Build Diary
Post by: Darren on June 23, 2013, 09:04:56 PM
Here's a vid of the door fitment, pay attention to the top flex, it's wise to address this before final bond, either do as I'm proposing or fill with expanded foam as some others do

http://www.youtube.com/watch?v=ud3dd3yHx0k
cheers
D
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on June 23, 2013, 09:44:55 PM
Nicely done nice to see you and dad building your dream car and dangerous great build video as ever whould love to have a fraction of your of your expertise  :D
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on June 23, 2013, 10:54:45 PM
Great progress Paul and Dad!

Keep the updates coming.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on June 23, 2013, 11:05:37 PM
whoa!! slow down mate! you are nearly up to me and Ive had mine 8 months!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 24, 2013, 12:50:37 PM
whoa!! slow down mate! you are nearly up to me and Ive had mine 8 months!  ;D

LOL, still a bit of a way till i get to where you're at matey...gotta get those arches sorted first  :-\
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on June 24, 2013, 01:28:24 PM
same here!

I thought I had them sorted, but stupidly, I had the car on axle stands, as soon as I stood it on the ground, the tyres rubbed in a different place  :( :(  ...  a little tip for you!!

break out the hammers!!

I was gunna bond my rear end on yesterday, but the weather was awful, so I couldnt get the car out of the garage to do the job correctly....maybe next weekend...
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 29, 2013, 08:34:26 PM
quick one guys - on the track rod ends. obviously i need to take them off, cut the thread down and then fit the extenders. but for removing the originals, how exactly do you do it? attached is picture or the originals showing from what i can see, only 2 areas that can be turned.. A and B. can someone tell me what to do? Is nut A fixed and you turn the B part or vice versa. At present the hub is off the car, so the track rod is not attached to anything. does it need to be fixed to the hub to disassemble? sorry for such a basic request but can't find this in the MR2 owners manual that Phil supplied.
Title: Re: Paul's 4thirty Build Diary
Post by: mantav8 on June 29, 2013, 09:03:13 PM
quick one guys - on the track rod ends. obviously i need to take them off, cut the thread down and then fit the extenders. but for removing the originals, how exactly do you do it? attached is picture or the originals showing from what i can see, only 2 areas that can be turned.. A and B. can someone tell me what to do? Is nut A fixed and you turn the B part or vice versa. At present the hub is off the car, so the track rod is not attached to anything. does it need to be fixed to the hub to disassemble? sorry for such a basic request but can't find this in the MR2 owners manual that Phil supplied.

Loosen nut 'A' it's a lock nut.Then uncrew track rod end off track rod at 'B'
 ;)
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on June 29, 2013, 10:55:49 PM
as Mantav8 said, also undo castle nut and hit the end of stub axle with a hammer directly on the end where the line ends
hammer blows inline with the cast line, dont hit the bolt after castle nut removal, that rarley works, then twist off track rod end
MADMAN 
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 30, 2013, 07:37:42 AM
Cheers guys, thing is I have already removed the hole rod from the hub but haven't undone nut A yet.  Am i still gonna be able to undo nut A without it being attached to the hub? Or is the only way for it to undo is if the whole thing is still supported by being attached to the hub.  :-[
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 30, 2013, 09:06:03 PM
Quick update. Total Build time 49 hours.

Not a great deal to report but Dad has been doing bits and bobs this week. Finished rear light holes, rear grill hole and number plate access panel. On the front clip, the lip at the front has been ground back to allow the doors to open inside. Number plate light holes cut and access holes under sill at front cut.

Front clip. You need to grind back the lip to allow the doors to open inside. That lip is there only for strength while in transit
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130630FrontClipEdge_zpsb80faa5e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130630FrontClipEdge_zpsb80faa5e.jpg.html)

Number plate lights
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130630NumberPlateLights_zpscc063499.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130630NumberPlateLights_zpscc063499.jpg.html)

Rear Grill Hole
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130630RearGrillCutout_zps43ee06b2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130630RearGrillCutout_zps43ee06b2.jpg.html)

I had the front bumper at home on saturday and started to back trim out the vent hole. Grinder worked perfectly and got a nice clean edge. Was just about the cut the rest using the dremmel when I realised had left the attachment at Dad's house! DOH!!  >:( so couldn't carry on. Never mind, have ordered another attachment so we have one each from now on

Back Trimmed
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130630BumperBackTrimmed1_zps888248cf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130630BumperBackTrimmed1_zps888248cf.jpg.html)

From other side
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130630BumperBackTrimmed2_zpsda3a0b21.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130630BumperBackTrimmed2_zpsda3a0b21.jpg.html)

That's it. I am going over Monday evening as i just cannot wait till Thursday to work on her!! Gonna crack on with front suspension now that I have the ball joints.

Man, what great weather we had today. Simply cannot wait till the car is done and i can drive around in weather like we had today!
 
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on July 01, 2013, 10:27:44 AM
great progress mate..keep the pics coming!
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on July 02, 2013, 07:57:07 AM
Keep up the good work buddy you will get there :)
More pics too please
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 02, 2013, 09:18:47 PM
Total Build Time: 54 Hours

So all front suspension is basically done now, including the front spacers. All thread locked as well. Dad has family staying with him and the guy is a mechanic, so big, big thanks to him for helping with the suspension.  ;D Also back trimmed the top wing holes. Pictures below:

Wing holes - loving the back trimming technique
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130702WingHole1_zps259c1c0f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130702WingHole1_zps259c1c0f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130702WingHole2_zps9dfb5b91.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130702WingHole2_zps9dfb5b91.jpg.html)

Rear clip with access panel cut out behind the number plate, along with number plate lights trial fitted
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130702RearClip_zps8d4a2667.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130702RearClip_zps8d4a2667.jpg.html)

Sill holes cut
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130702SillAccessHole_zpsb97acad3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130702SillAccessHole_zpsb97acad3.jpg.html)

Front Passenger Suspension
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130702PassWheel2_zpsf693ed83.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130702PassWheel2_zpsf693ed83.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130702PassWheel1_zps44791658.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130702PassWheel1_zps44791658.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130702PassSuspension1_zpsd8e4909b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130702PassSuspension1_zpsd8e4909b.jpg.html)

Front Drivers Suspension
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130702DriveSuspension1_zps2cd49518.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130702DriveSuspension1_zps2cd49518.jpg.html)

Next jobs: etch and trim rear clip and door sills and to fit back the track rod ends with the extenders and then we can test with wheels and check the arches. Bang Bang Bang  ;D While the back clip is upside down will use it as an opportunity to trail fit the rear diffuser. Will certainly be easier drill holes on the return edge with it upside down than when it is on the back of the car the right way up!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 05, 2013, 10:30:34 PM
"COME ON TIM!!!"

Right now that Murray is through to his 2nd Wimbledon final, down to business.

Total Build Time: 56 Hours

Thursday night we did the following: fitted back all brake components on the front, cut the track rod ends and adjusted the tracking, tried the front wheels for arch scrub, and banged them a bit. Nearly clears but need to bash the seam in more. Will have a good go tomorrow. Big thanks to 'Luce' for helping with all the suspension/brake parts.

Photos below:

Cutting the track rod end:
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130704TRECut_zpsfb061abe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130704TRECut_zpsfb061abe.jpg.html)

Passenger Side Completed:
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130703PassSuspension1_zps6c4298f8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130703PassSuspension1_zps6c4298f8.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130703PassSuspension2_zps670d7fd2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130703PassSuspension2_zps670d7fd2.jpg.html)

Driver Side Completed:
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130704DriverSuspension1_zpsb92941aa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130704DriverSuspension1_zpsb92941aa.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130703DriversSuspension2_zps18981ab3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130703DriversSuspension2_zps18981ab3.jpg.html)

'Luce' cheers for all your help
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130704Luce_zps39b46519.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130704Luce_zps39b46519.jpg.html)

Arch Scrub: The area to bang back is all the way up to the seam. The wheels turn nearly on full lock but gets caught on this seam. Will have another go on them tomorrow.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130704ArchRub_zps9d9067a0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130704ArchRub_zps9d9067a0.jpg.html)

Finally, with the wheels on, had to get a photo with the doors panels and front clip on..well excited
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130704CarEnd_zpsbc935342.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130704CarEnd_zpsbc935342.jpg.html)

Tomorrow I am spending a full day on her which will be the last full day for a while. Hope to sort the arches, sort the back clip and at least place the back clip on the car for the start of the dry fit. More updates soon!

Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on July 05, 2013, 10:46:43 PM
Brilliant work mate....

That seam was a pain in the bum for me as well, I think I might need a bigger hammer! I still need to bang mine in another centimeter,  I keep on hammering and it doesnt seem to move any further!

Ah well...ill keep banging!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 06, 2013, 10:41:57 PM
Total Build Time: 64 Hours

Good solid 8 hours on her today. Here's what I got up to on the hottest day of the year so far!  ;D (BTW - I'm bloody knackered now!)

First, started etching the whole rear clip. I found using an angle grinder with a sanding disc (40 grit) and bounce it along the GRP to create little dips to rough it up worked well. Dad tried a wire brush during the week and it didn't really work.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706RearEtched2_zpsc9ce757e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706RearEtched2_zpsc9ce757e.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706RearEtched4_zps42a66e1f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706RearEtched4_zps42a66e1f.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706RearEtched3_zpscda8835f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706RearEtched3_zpscda8835f.jpg.html)

Next as rear clip was upside down, I trial fitted the rear diffuser as it is much easier to drill the holes this way up as opposed to when the rear clip is on the car!
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706Diffuser2_zps6d05739f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706Diffuser2_zps6d05739f.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706Diffuser1_zps166f15f9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706Diffuser1_zps166f15f9.jpg.html)

Next got to work on the lower air intakes and back ground them out
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706LowerScoop_zps1c945cd1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706LowerScoop_zps1c945cd1.jpg.html)

Upper intakes all done
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706UpperScoop_zps0dc152ad.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706UpperScoop_zps0dc152ad.jpg.html)

Rear clip all etched ready to be primed
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706RearEtched1_zps61a589b1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706RearEtched1_zps61a589b1.jpg.html)

Gave it a clean to get rid of dust
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706RearPrimed3_zps869d7d10.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706RearPrimed3_zps869d7d10.jpg.html)

Primed all the etched areas
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706RearPrimed1_zpsd35a01a0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706RearPrimed1_zpsd35a01a0.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706RearPrimed2_zpsa15e4cbb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706RearPrimed2_zpsa15e4cbb.jpg.html)

While that was drying I got to work on the front "god-forsaken" arches. Had a good banging session (oooeeer!) and after putting wheels on and off 3 times we are  "All Clear for take off"

Passenger Side
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706PassArch1_zps47ccbc75.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706PassArch1_zps47ccbc75.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706PassArch2_zps935f3199.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706PassArch2_zps935f3199.jpg.html)

Drivers Side
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706DriverArch2_zpsd8199b92.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706DriverArch2_zpsd8199b92.jpg.html)
(Don't worry, I will get that split welded up)

So Dad got home from work at about 1pm and we could get to work on getting the rear end on. Big thanks to Luce and Dad for all their help. Got it all on and MY GOD! what a transformation. Very minimal adjustments needed to the clip to get it all sitting right. Had to grind a few bits away to make it flush etc.. but on the whole, it fitted lovely. Door skins were put back on and 2 screws place front and back of each door so they are fitted. Secured the front sills to car body. Think I am happy with the gaps. Got 4mm max all around. Although now every car I see on the street I am checking the gaps on them!   :-\ I also secured the clip to the inside of the door sill using the original MR2 bolts holes and bolts. Just the lower on on each side. Sorry no pictures.

Then I just laid the front clip on for the photos  ;D. Then it was time to go home and take my girls out for dinner!
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706Rear1_zpsfee1e2bd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706Rear1_zpsfee1e2bd.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706FullCar1_zps8fef17d3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706FullCar1_zps8fef17d3.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6154_zps071f0503.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6154_zps071f0503.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6153_zpse8a38c76.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6153_zpse8a38c76.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706Rear2_zps612dc859.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706Rear2_zps612dc859.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130706Rear3_zps7ffad1cb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130706Rear3_zps7ffad1cb.jpg.html)

Gonna sleep well tonight!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on July 06, 2013, 10:44:57 PM
Looking good mate. Nice work.
Title: Re: Paul's 4thirty Build Diary
Post by: Darren on July 07, 2013, 09:10:50 AM
It's amazing that all the hard work you just don't see, yet put on some grp panels and you have a 'Ferrari'
 Great progress
D
Title: Re: Paul's 4thirty Build Diary
Post by: demjackets on July 07, 2013, 07:57:37 PM
Great Work! The build is so much fun. Enjoy it while it last.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 07, 2013, 09:20:44 PM
Here's a quick video of a walk around of my DNA 430 after 64 hours work (click on picture to view):

Main jobs done in this time:

>Car stripped down
>Rear suspension fitted
>Front suspension fitted included wheel spacers
>Front arches banged back to clear
>Rear panel prepared including holes cut and etched and primed
>Door skins cut to fit and dry fitted
>Rear panel placed on car and dry fitted
>Door handle mechanism fitted
>Front bumper/headlight brackets fitted

(http://i1315.photobucket.com/albums/t597/pjlucas1/th_20130706DNA4thirtyBuildafter64hours_zpsc8c5b7ed.jpg) (http://i1315.photobucket.com/albums/t597/pjlucas1/20130706DNA4thirtyBuildafter64hours_zpsc8c5b7ed.mp4)

The front clip is not dry fitted here. It is just placed on the car for the video for (dramatic  ;D ) effect. On the video, that isn't people swearing, that is my Dad speaking Lithuanian. I hope all you DNA convertible owners took full advantage of the weather today! What a scorcher! ;D

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 07, 2013, 09:22:32 PM
oooo just noticed I am now a full member! Promotion!
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on July 07, 2013, 10:03:39 PM
Really nice job mate thanks for the video
 ;)
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on July 07, 2013, 10:09:39 PM
Nice work mate
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 12, 2013, 01:36:53 PM
Recent jobs done – nothing major – all fiddly bits, but need doing obviously….

•   Petrol flap cut out – needs finishing off
•   Doors skins etched and primed
•   Door handles and cabinet hinges etched and primed
•   Split in drivers arched prepared for welding – hopefully this will be done Sunday
•   Rear spacer threads all checked and are fine
•   Brackets added to original doors for the door skins to hang on/be glued to remove the flex from the passenger door, picture below shows the passenger door. These will also be spot welded to the door. On the tops of these brackets I will add glue to also attach the top of the door to the car.

As for the door flex issue, i don't think you need to go crazy here because i cannot see people really leaning across the whole of the top of the door because the actual window glass doesn't go completely down into the inside of the door anyhow... on the door glass you can see a line i have drawn where the top of the door skin meets - so you have a good inch of glass poking out here..

(http://i1315.photobucket.com/albums/t597/pjlucas1/21307012DoorBracketsbmp_zps7ad662e5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/21307012DoorBracketsbmp_zps7ad662e5.jpg.html)

Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on July 12, 2013, 03:04:58 PM
nice work, keep the pics coming  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 14, 2013, 08:48:37 PM
Total Build Time: 70 Hours

Quick update. Split in front arch was prepared for welding on Thurs and metal screwed back into place.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130714ArchWeld_zpsa4755678.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130714ArchWeld_zpsa4755678.jpg.html)

Terry the welder came over today and said it won't need welding after all. Just fill in the gaps with filler and then under seal it all.

Also the door brackets I did on Thursday, I planned for Terry to spot weld these as well, but his advice was rivets instead. So Dad's has gone to town and started replacing all screws on the door brackets etc.. with rivets. Says they are much more secure.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130714DoorRivets1_zps9fc23acf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130714DoorRivets1_zps9fc23acf.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130714DoorRivets2_zps1fdb685f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130714DoorRivets2_zps1fdb685f.jpg.html)

Finally got round to cutting out front bumper side vents holes
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130714FrontBumper2_zps3ecc6dfb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130714FrontBumper2_zps3ecc6dfb.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130714FrontBumper1_zps29cf21b3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130714FrontBumper1_zps29cf21b3.jpg.html)

Next jobs: Body fill in the gaps in the arch. Hammerite the arches where they have been bashed back, and then under seal all 4 arches.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 21, 2013, 09:30:10 AM
Door bracket all done and riveted instead of screws
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130721DoorBrackets1_zps5887ef24.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130721DoorBrackets1_zps5887ef24.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130721DoorBrackets2_zpsc2915101.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130721DoorBrackets2_zpsc2915101.jpg.html)

Front drivers arch split finally filled and freshly under sealed.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130721DriverArch2_zpsd784e606.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130721DriverArch2_zpsd784e606.jpg.html)
Under seal still a bit wet in photos
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130721DriverArch1_zps1261551e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130721DriverArch1_zps1261551e.jpg.html)

Front passenger arch also undersealed
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130721PassArch1_zps235d38a0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130721PassArch1_zps235d38a0.jpg.html)

Lower exhaust can be seen through gap above the rear diffuser so decided to paint that black in high temperature pant. Will do the top of the lower exhaust as well for a better finish, as well as the rear bumper bar in black hammerite.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130721LowerExhaust_zps7ad426e8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130721LowerExhaust_zps7ad426e8.jpg.html)

Finally cut out slits in rear grill hole
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130721RearHoleCutout_zpsbbbe58f6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130721RearHoleCutout_zpsbbbe58f6.jpg.html)
 
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on July 21, 2013, 03:17:55 PM
 ;) keep at it Paul and you will soon be in rudys shoes all the hard work pays off you and your dad make a great team pal ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 21, 2013, 09:53:35 PM
Total Build time: 75 Hours

As today was nice and peaceful in the back garden, I thought I'd get the jigsaw, dremmel and files out and do a bit of cutting!

Cut out the interior door handle holes in the arm rests

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130721DoorArmRests_zps4a8497fe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130721DoorArmRests_zps4a8497fe.jpg.html)

Then the dummy engine. I want to make it as real looking as possible, and I think being able to see through parts of the engine 'box' will make it look more real. I have cut out all the 'flat' parts of the dummy engine, so you'll be able to see through below.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130721DummyEngine3_zps2bbad5e7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130721DummyEngine3_zps2bbad5e7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130721DummyEngine2_zps0c0caa6f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130721DummyEngine2_zps0c0caa6f.jpg.html)

Parts of the dummy engine are really, rough and I don't think I could ever get them perfect for bare paint only. Plus I plan to cover the engine mounting brace bars in real aluminium so the bars are real metal, and the gaps I have cut out I may fit a tight mesh in them to form some sort of floor. Plenty of other metal bits, tubes and allen bolts as well.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130721DummyEngine1_zps8d8327fe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130721DummyEngine1_zps8d8327fe.jpg.html)

Watch this space!  ;D

 
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on July 21, 2013, 11:26:15 PM
Looking great. I used black ali mesh and it looks good.
Keep up the good work and enjoy it  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 22, 2013, 07:14:49 AM
Cheers for the comments Ghall and Rudy..
Paul  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Darren on July 22, 2013, 03:00:36 PM
The extra attention to detail on the engine cover seems to becoming part of the build. It Does add that wow factor when looking in the boot/engine glass
D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 22, 2013, 09:52:24 PM
that's right D. the way i see it, there aren't many cars in the world where you can can see the engine behind glass at all times. it is a very special thing. so it is just as important for the dummy engine to look as real as possible as it will spoil the look of the car if it looks too fake...we'll see how i get on.... ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on July 23, 2013, 12:44:42 AM
Coming along nicely Paul.

Keep up the great work.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Nik the Greek on July 23, 2013, 10:51:20 AM
Dear Paul,you and Rudy and Phil  YOU ARE KILLING ME.
Nice work friend.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 26, 2013, 09:32:50 PM
Nik, now that Rudy has (literally 8)) driven off into the sunset, it is just me, Phil and Dangerous left doing the 430's. Come on people, someone else get building.. It's awesome fun!!! Got a full day on her tomorrow. Hopefully aiming to get the front done as well as door handles...

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 26, 2013, 10:28:32 PM
where the hell is the 19mm socket?

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130701Search_zps64aef29d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130701Search_zps64aef29d.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 28, 2013, 07:38:30 PM
Thursday night I spent 3 hours doing little jobs getting the car ready for front clip fitting on Saturday. Jobs included:

Fitting door skins back for final fit
Sill adjustments
Finishing off under sealing all arches and painting various bit black for a clean look
Secured the front brake caliper pipes with cable clips to the suspension legs
Put all 4 wheels back on so I can drive the car out of the garage on Saturday

Also took over dummy engine to see what it would look like now I have cut various bits out - will have to get rid of the Toyota 16 valve writing! Haha :-\
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130725DummyEngine1_zps94f1d6e3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130725DummyEngine1_zps94f1d6e3.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130725DummyEngine2_zps6bfe8850.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130725DummyEngine2_zps6bfe8850.jpg.html)

Rear Arch all blacked out
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130725RearArchBlack1_zpsae0632fa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130725RearArchBlack1_zpsae0632fa.jpg.html)

Front Arch all blacked out
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130725FrontArchBlack_zps3855ab2a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130725FrontArchBlack_zps3855ab2a.jpg.html)





Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on July 28, 2013, 07:51:05 PM
Excellent work Paul,love what your doing with the fake engine...gunna keep my eye on that piece of work!...Im saving mine to do when the car goes to paint shop, as I will be lost for 2-3 months!

Also, I like the cable ties for the brake pipes, I pondered about these, as the bracket no longer reaches the pipes bracket and you cant move it!, would this be a safety/MOT failure if you didnt secure it I wonder.....

I also noticed that your wheel spacers are not powder coated! I must have been lucky when I got mine as they were...I would recommend getting them done when you send it to the body shop!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 28, 2013, 07:58:01 PM
Cheers Phil - my mate, Terry does MOT's so will ask him about that. Does anyone else know? Do the spacers need to be power coated? Surely they are stainless steel?
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on July 28, 2013, 08:03:12 PM
The picture of your front one looks rusty already!!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 28, 2013, 09:04:46 PM
Now onto Saturday.... I spent a good 8 hours working on my tan yesterday  8). Rain held off which was great, so this is what I got done:

Firstly, started up the car and reversed it out of the garage. Pleased to report the brakes were all working fine, seeing as they hadn't been tested since I did the front spacers.

During the week Dad had painted the rear bumper bar and lower exhausts in black paint for a cleaner look
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130727RearBlackedOut_zps55284c4c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130727RearBlackedOut_zps55284c4c.jpg.html)

Next I fitted the splitter to the front bumper. Drilled 4 holes and then counter sunk them slightly, and bolted it with 4 countersunk allen bolts to keep them flush.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130727FrontBumper3_zps2183fe4a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130727FrontBumper3_zps2183fe4a.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130727FrontBumper2_zpscc3e8fe8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130727FrontBumper2_zpscc3e8fe8.jpg.html)

Then I thought I'd fit the rear diffuser to see what it looked like. Not entirely happy with the fit on the driver side. Needs a little filling and shaping to get it flush with body work, but that can be for another day.
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727RearDiffuser_zpsc3a4da84.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727RearDiffuser_zpsc3a4da84.jpg.html)

Next the front wheels came off ready to fit the front clip - definitely need them off out of the way for this job!
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130727PassArchBlack_zpsabed2bc0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130727PassArchBlack_zpsabed2bc0.jpg.html)

Front Sill
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727PassSill_zps2965ead1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727PassSill_zps2965ead1.jpg.html)

So the fitting of the front clip began! My word, what a job that is! I did it on my own, but if there is another pair of hands around I recommend it as there is a lot getting up and down to open the door etc...My back was killing me. I did the passenger side first:

I used the hole at the top of the wing near the windscreen as a starting point. Drilled it out quite large so I had room for it to be adjusted. I used a bolt and packed it out with a few washers underneath (cheers for the advice Phil). If you try and do this bolt up really tight then it just pulls the wing down and the door catches again, so don't fully do it up. I will fill the void under there with sealant anyway to fill the gap when I bond everything on. Then I secured the bottom of the wing with a bolt and then the adjusting began. Dad had ground back the return on the edge to pretty much flush, but I still needed to do a little filing back towards the top.

You need to make the curve at the top of the wing (where the door goes under) 'pop' up a little to make it clear, and I found if you put a screw in the panel after where the fake panel cut is in the windscreen pillar, this does it. (see photos). I will replace this screw with a countersunk one when doing the final fitting.

(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727PassFrontClip1_zpsa5eecdeb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727PassFrontClip1_zpsa5eecdeb.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727PassFrontClip2_zps92a7c9d5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727PassFrontClip2_zps92a7c9d5.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727PassFrontClip3_zps080b8265.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727PassFrontClip3_zps080b8265.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727PassFrontClip4_zps30b5ec30.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727PassFrontClip4_zps30b5ec30.jpg.html)

Next the driver side. Followed the same method, although I had to grind down more of the lip towards the bottom of the panel (the vertical part) as the door was catching lower down.
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727DriversFrontClip1_zpsb843417e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727DriversFrontClip1_zpsb843417e.jpg.html)

So finally this is where we were after about 4 hours. Needed to have a beer!  ;D
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727DriversFrontClip2_zpsdf9b51b6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727DriversFrontClip2_zpsdf9b51b6.jpg.html)

Next up was front bumper. I had previously drilled out the 6 holes at the top to a large size, but they needed to be made bigger so I re-drilled them. Then it was just a case of bolting it on. Simples.
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727FrontBumper1_zps11615c48.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727FrontBumper1_zps11615c48.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727FrontBumper4_zps253b18af.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727FrontBumper4_zps253b18af.jpg.html)

By this point Dad was home from work, so we put the front wheels back on and then put the bonnet and rear deck on for some pictures. I also wanted to see how the dummy engine would look through the rear deck.
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727RearDeck1_zps8146f342.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727RearDeck1_zps8146f342.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727RearDeck2_zps68163e63.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727RearDeck2_zps68163e63.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727FullShot1_zps8e855e6f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727FullShot1_zps8e855e6f.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727FullShot3_zps573516e6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727FullShot3_zps573516e6.jpg.html)

Next, we tried to bond the door handles. Only managed to get the passenger side done, but it is now fully working.
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727PassHandle1_zpsa81dc92a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727PassHandle1_zpsa81dc92a.jpg.html)

I did plan to use rivets but I didn't have long enough ones, so we tried a thin screw headed bolt which worked. Dad has since filled over the screw heads. Main thing is it works!
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727PassHandle2_zps8819d265.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727PassHandle2_zps8819d265.jpg.html)

By this point it was 4pm so thought I'd call it a day and drove the car back into the garage with a big grin on my face.... ;D
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727Final1_zps1c12b1e7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727Final1_zps1c12b1e7.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/207130727Final2_zpsfe2aec33.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/207130727Final2_zpsfe2aec33.jpg.html)

It will be a while before I have a full day on the car again, but I've got plenty of things to be getting on with. I've got loads of bit for the dummy engine which I can do in the evenings after work at my house.

Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on July 28, 2013, 09:17:40 PM
looking great Paul...well done mate.....
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 28, 2013, 09:18:43 PM
Last update for you tonight (I promise!)

Below is a short film of the car after 88 hours work. Click on picture to play. It might come up as a small blue ? icon below instead of a picture, but click on that  - it still works. Enjoy!  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/th_20130727DNA430After88HoursEdit_zps6118028d.jpg) (http://i1315.photobucket.com/albums/t597/pjlucas1/20130727DNA430After88HoursEdit_zps6118028d.mp4)
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on July 29, 2013, 01:33:22 AM
Nice. Like it. Well done.  :)
Title: Re: Paul's 4thirty Build Diary
Post by: ENZO on July 29, 2013, 05:49:38 AM
Nice wheel choice on the front there Paul,  What size are they - 19in?
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 29, 2013, 07:15:35 AM
Thanks ENZO, yes they are 19 inch. Dimensions are:

Fronts: 215/35/19
Rears: 245/35/19

Cheers
Title: Re: Paul's 4thirty Build Diary
Post by: ENZO on July 29, 2013, 09:43:00 AM
Thanks ENZO, yes they are 19 inch. Dimensions are:

Fronts: 215/35/19
Rears: 245/35/19

Cheers


Sweet! whats the PCD? 5x114.3 or 5x108 perhaps?
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 29, 2013, 11:00:08 AM
depends on the spacers that you have. the spacers DNA supplied to me with my kit were 5x120mm PCD
Title: Re: Paul's 4thirty Build Diary
Post by: ENZO on August 01, 2013, 03:45:48 AM
depends on the spacers that you have. the spacers DNA supplied to me with my kit were 5x120mm PCD

oic cool!, what width rim are you running on front and back? (appreciate you humoring me and my questions) :)
Title: Re: Paul's 4thirty Build Diary
Post by: Darren on August 01, 2013, 06:25:20 PM
Nice progress Paul, the wheels change the whole look of the car when fitted with the body panels.
D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 02, 2013, 09:23:47 PM
Total Build Time:  91 Hours

Not a lot to report, but spent 3 hours last night getting the door handles right. A fiddly job, but obviously essential. Think I have got them as best I can. Already filled in the bolts holes.

Passenger Handle
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130801PassDoorHandle_zps86f270d1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130801PassDoorHandle_zps86f270d1.jpg.html)

Drivers Handle
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130801DriversDoorHandle_zps44179129.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130801DriversDoorHandle_zps44179129.jpg.html)

I am now at a stage where I cannot progress without bonding on doors, back and front, so this is what is next. Will start with doors on Tuesday night.

 
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 02, 2013, 09:40:03 PM
depends on the spacers that you have. the spacers DNA supplied to me with my kit were 5x120mm PCD

oic cool!, what width rim are you running on front and back? (appreciate you humoring me and my questions) :)


I think it is 8 inches front and back
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on August 03, 2013, 02:45:51 PM
Nice job Paul
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 04, 2013, 08:22:40 AM
Bit more work on the dummy engine yesterday..

Finished off the metal bar on one side yesterday. My original plan was to just cover the existing support bars with real metal, but in the end I found it best to cut away the shorter angled part and replace completely with the aluminium channel I had bought. After much head scratching I joined the 2 with a bracket and bolts and used some of the allen bolts I had bought for decoration to hold it all together. Was touch and go, but very pleased with the result now.

What I did is for the longer part of metal I bought an L shaped piece and bascially covered the orignal plastic bar. Mine slopes upwards towards the front of the car as the L shaped piece I could get was only 40mm x 40mm. If you fit it completely flat to the orignal plastic bars a lot of the metal will stick lower than the underside of the whole dummy engine and might catch on things. The angle part is an aluminium channel 20mm x 40mm x 20mm.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130804Bracket1_zpsefa0dbbe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130804Bracket1_zpsefa0dbbe.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130804Bracket2_zps3383554f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130804Bracket2_zps3383554f.jpg.html)

This is all easy to unbolt when I paint the whole thing, and will also give the aluminium a paint as well, as the building part scratches it a bit.

Next I got to work on the centre mesh part. A bit fiddling, but got it done. Again used some Allen bolts to hold it all in place. I will stick it as well at the end, but for now, this holds very well.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130804CentreMesh_zps5a8ef156.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130804CentreMesh_zps5a8ef156.jpg.html)

Then did the mesh to cover the metal work I had done
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130804BothMeshes_zpsbc22ffbf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130804BothMeshes_zpsbc22ffbf.jpg.html)

So this is the view from above
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130804TopView_zps39b01e03.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130804TopView_zps39b01e03.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130804BraceBar1_zps4fc87214.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130804BraceBar1_zps4fc87214.jpg.html)

Where I had to cut away the shorter angled part, I filled in around the real metal part for a better finish when painted
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130804BraceBarFilled_zpsfcc9ab34.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130804BraceBarFilled_zpsfcc9ab34.jpg.html)

So this is where we are at now
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130804BraceBar2_zpsbe8834e8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130804BraceBar2_zpsbe8834e8.jpg.html)

Added Allen bolts to the main engine head.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130804AllenBolts2_zps2f4af36d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130804AllenBolts2_zps2f4af36d.jpg.html)

I plan to not paint a drop until all building has finished. The GRP can be very thin in places, and you don't want to be drilling holes for Allen bolts etc... with it painted, as sometimes bits of GRP chip off etc...I had this on some of the Allen bolts on the engine head which is why you can see some filler on some of them...

I am not entirely happy about the centre mesh. The pot bit with the star shaped cap, looks like it is floating in air at the moment. I plan to extend the rest of it undernetah the measure so it looks like it has more depth. Just need to find a suitable cylindrical containter. My wife's tupperwear is in real danger!!!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on August 04, 2013, 08:49:44 AM
This all looks great Paul and is fantastic to see such attention to detail. Going to look awesome! :)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on August 04, 2013, 09:20:57 AM
Amazing mate!

This is gunna be one good looking fake engine!
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on August 04, 2013, 09:31:09 AM
Looking good Paul,
                            I did the same thing on mine and where the metal bars meet I used some grey mastic carefully squeezed to resemble a weld, quite affective ;D
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on August 04, 2013, 09:32:34 AM
VERY effective Madman...it fooled me!!

How do you guys think of these things?  ;D ;D ;D
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on August 04, 2013, 09:44:33 AM
Looking great Paul.
Nice work with the dummy engine.
Are you going to wire it up with Maff sensors, etc.?
Old printer cables will come in handy  :)
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on August 04, 2013, 11:53:51 AM
 :D well done Paul all adds to the realism and certainly gives the bay some depth
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 04, 2013, 08:41:55 PM
cheers for the comment guys, very kind.

Yes Madman, I had thought of doing something like that, so glad you said that. Yeah I'll certainly put in some wiring and extra pipe work as well Rudy. Got plenty of of printer cables in the shed so will use them yes - thanks for the tip. Have you got the part number for the vauxhall Maff sensors you got and how much were they?

Next questions for you gurus. Dad was trying to get the internal door cards to fit today, and tells me that along the middle of the door there is a piece of metal that sticks up further than the rest of the door, and as it protrudes it means, even if the door card lip is complelety cut out at this point, the door car will never sit flush with the exterior door skin.

I attached a picture with the offending piece of metal attached? Dad thinks it can be trimmed down. Has anyone else done this/know this issue/got any suggestions? Cheers chaps

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130804Door_zpsf22a18f8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130804Door_zpsf22a18f8.jpg.html)

Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on August 04, 2013, 11:13:49 PM
I trimmed mine down, I also run the angle grinder horizontaly front to back on centre of door card, then pulled it down to make the top edge run level with the door skin. using bridging filler and zink mesh to hold it together.
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 05, 2013, 10:28:52 PM
Cheers MADMAN. Will have a good look when I go over tomorrow. Tomorrow night is door bonding day! Wish me luck. Will also take dummy engine to see how it looks on the car.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 07, 2013, 01:15:37 PM
Next Question Gurus - car wiring.. thinking ahead here, but I am going to need to possibly extend wires for lights, electric mirrors etc... so was thinking about buying a selection of auto wires off ebay. Does anyone know what power rating would be sufficient?

Is something like the below sutiable (16A)

http://www.ebay.co.uk/itm/50M-AUTOMOTIVE-CABLE-KIT-1MM-16A-CAR-BOAT-LOOM-WIRE-50-METRES-10-X-5M-/251239196538?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item3a7f05e77a

thanks guys

Paul
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on August 07, 2013, 02:49:39 PM
Paul 16A gauge is good.
Check out CBS-online. Car Builders Solutions.
I bought a lot of my stuff from there.
Good prices and excellent service.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 07, 2013, 02:53:17 PM
Cheers Rudy, will check them out as well
Paul
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 07, 2013, 10:03:05 PM
Build time: 98 Hours

Did some more work on the dummy engine. Added some depth beneath the "2 pots" in the centre. For this I used 2 old paint tins. For the rear pots I used a 2.5 litre paint tin, cut down to 5cm deep and for the front smaller pot, I used a 1 litre paint tin (uncut). Primed and painted in satin black and then bolted underneath

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130806Engine1_zps44ab28aa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130806Engine1_zps44ab28aa.jpg.html)

Here the yellow arrow shows the 'depth' beneath the mesh
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130806Engine2_zpsc2b0370b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130806Engine2_zpsc2b0370b.jpg.html)

So thurs night I took it over to see how it looked on the car. To be honest I don't think it is necessary for the rear pot now. There isn't much room underneath as it hits part of the original car and you really cannot see the depth as it is so short anyway.

However the front pot seems to work well. The yellow arrow showing the depth through the mesh. There is still room underneath and the paint tin doesn't foul anything. I am hoping that when the rest of the dummy engine is painted the top of the small pot blends in more and looks more continuous above and below the mesh
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130806Engine3_zps58154365.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130806Engine3_zps58154365.jpg.html)

Here is another shot. I was thinking about adding some tubes or something to the paint tin, but tbh, when you have the rear deck on and with the glass, I really doubt you are going to see them. Maybe add it when all done if I am still not happy.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130806Engine4_zpsf5987ae8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130806Engine4_zpsf5987ae8.jpg.html)

Next the door cards. Dad is working on getting them to fit, but as I said previously part of the door is still too high. So I got the angle grinder out and trimmed them down. Still need a bit of work but the bulk is done. Circled are the bits I trimmed.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130806PassDoor1_zpsfd281f46.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130806PassDoor1_zpsfd281f46.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130806PassDoor2_zpsb40d47de.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130806PassDoor2_zpsb40d47de.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130806PassDoor3_zps16a85699.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130806PassDoor3_zps16a85699.jpg.html)

So on to the main event. Door bonding. No photos, but not a lot to show really. A bit stressful at times but organisation is the key. To all futures builders here is a check list  ;)

>Put tubes of betaseal etc in hot water for 1 hour before you are ready to bond
>Use a metal sealant gun (like Phil suggests), not the plastic ones
>Wear disposable gloves at all times and have loads of extra pairs ready
>Have loads of spare old rags for wiping off excess sealant
>Have a bin nearby to chuck all messed rags into asap so the mess is out of the way
>Have all tools/screws etc.. very nearby ready to screw back panels asap
>Have a bottle of meth's very close by to wipe unwanted sealant off panels - you will get it on panels where you shouldn't
>Ideally have someone else to help
>Try your door handle as soon as possible just in case things don't work as they should

Next is bonding on back and front. Till next time....  ;D


Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on August 07, 2013, 10:54:34 PM
brilliant progress mate!

great photos and great tips.....love what your doing with the engine!
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on August 08, 2013, 09:52:25 AM
you could use 2" masking tape close to bonding areas, two or three strips to save some cleaning, just remember to remove before bond sets.
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 08, 2013, 08:50:31 PM
Paul 16A gauge is good.
Check out CBS-online. Car Builders Solutions.
I bought a lot of my stuff from there.
Good prices and excellent service.

Rudy, just checked out CBS. OMG that is heaven for me! Ordered the catalogue as soon as I could. That will def past the cold bum test!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 08, 2013, 08:56:03 PM
I trimmed mine down, I also run the angle grinder horizontaly front to back on centre of door card, then pulled it down to make the top edge run level with the door skin. using bridging filler and zink mesh to hold it together.
MADMAN 8)

Madman, this cutting you did on the door card -  I don't quite get it. Do you mean you basically cut the door card clean in half in the middle to get it to line up with the top of the door skin and then re-joined it back together?  Dad has done work on them today and says they fit pretty well, but I wont see them for a bit. Have you got any pictures?  Cheers.
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on August 09, 2013, 03:31:35 PM
Paul,
Glad CBS is good for you.
Like I said, they are great.
Rudy
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on August 09, 2013, 11:55:02 PM
I trimmed mine down, I also run the angle grinder horizontaly front to back on centre of door card, then pulled it down to make the top edge run level with the door skin. using bridging filler and zink mesh to hold it together.
MADMAN 8)

Madman, this cutting you did on the door card -  I don't quite get it. Do you mean you basically cut the door card clean in half in the middle to get it to line up with the top of the door skin and then re-joined it back together?  Dad has done work on them today and says they fit pretty well, but I wont see them for a bit. Have you got any pictures?  Cheers.
            from memory I cut horizontally backwards from front aprox 18",   aprox 6" from top, allowing the top edge to be lowered to be more inline with the outer door skin. Having done that, last year I bought a new Ford Focus diesel est, guess what, the door card rises at the front aprox 1"  ::)
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 10, 2013, 06:44:40 PM
Nice. Cheers for tips. Will def take that on board madman.
Paul
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 26, 2013, 08:59:34 PM
Hi Guys, been away for a couple weeks on holiday but got back Saturday and spent time working on car Sunday and Monday.

Sorry there is no pictures but nothing has changed in appearance really. While I was away Dad did a few jobs. He painted and lacquered the spacers black and relocated the washer bottle. We decided to go for a slimline one and mounted it one the outside of the 'frunk', so it is out of the way of the headlamps.

Sunday was busy- it was rear end bonding day! I removed front wheels and front bumper, removed front clip, removed rear clip, etched and primed b pillars and back areas, removed old fuel and breather pipes, and extended fuel hose but didn't have correct hose clips to do anything further and then finally we bonded on rear clip, including b pillars and sills.

Today I wanted to get the front clip bonded as we are at a stage now where we couldn't move forward without the main bonding being done, so we bonded on front clip, bonded fuel cap into housing, and then refitted front bumper.

Had a go at doing the exhaust and it seems that the brackets/clips I have got don't seem to do the job enough. Did anyone else have this problem? Did you need to buy additional brackets/clamps? I think in order to do a good job of it we are going to the make some new brackets and attach to the bumper bars to really hold the pipes steady. How do people support the horizontal pipe that comes out of the silencer on the drivers side as there seems to be nothing to attach any clamp/bracket to.

Total Build time now 114 Hours

Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on August 26, 2013, 09:28:30 PM
Hope you had a great Holliday bet you couldn't wait to get on with the build it will be worth all the hard work its going well  ;)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 26, 2013, 09:49:13 PM
cheers Ghall, yes was itching to get back and get some work done. thanks for your kind comments
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on August 27, 2013, 07:03:23 AM
great progress make, you are now officially ahead of me!!!
I had problems with my exhaust, I had to slot the ends of the u bend as it waz the same diameter as my tips...it only just fits in, but I intent to get them welded to gether when im nearer the end....
check my build thread I did take a lot of pics of the exhaust and yes, my brackets with the threads dont seem long enough to get the exhast to sit correctly.....
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on August 27, 2013, 03:17:41 PM
To me, the exhaust system is the weakest part of the kit. I was never really happy with mine.

I hate to point out a negative on any aspect of DNA, cos let's face it, there really isn't much to complain about. I just think the exhaust could be a better fit and of higher quality. Even if it increased the overall price by a couple hundred pounds it would definitely be worth it.

How about it DNA, any plans to upgrade the system?

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on August 27, 2013, 04:37:35 PM
+1. I agree with Beany's comments 100%
This is in a constructive and positive way.

I had to do the best I could at the time and still not happy with it, but as I plan some engine mods I let it be, but if I paid a little bit more for a better system in the first place, it would have been more cost effective in the long run.

Also the sound of mine is nothing like some others. Madman and mine have in theory the same system, including manifold, etc, but sound totally different.

Again this is purely constructive.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 27, 2013, 09:28:09 PM
Thanks Guys, I agree with everything said above and I don't want to cause any bad feeling with DNA etc.. Maybe it is just no one has ever mentioned it to them? When I picked my kit up, Brian said the DNA boys have never done an exhaust themselves. All turn-key's they build get sent to the local exhaust centre to be fitted after painting. So maybe they just don't know. If they did fit them themselves I'm sure they would come up with something that works a lot better bracket wise, but when you run a business you can't do everything as it just isn't always efficient. What ever I do, I'll make sure I put pictures on here for all to see..  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on August 28, 2013, 09:09:35 AM
I altered one of my clamps with a welded bolt and 2 nuts so that I could adjust the position and tweek it during fitting. Worked well for me in getting the tailpipes sitting "right".  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 02, 2013, 04:49:34 PM
Quick update for you. Apologies for lack of pictures, but left the camera at Dad’s and my iPhone camera is pretty poo. Will post some soon when I go over to do the car tomorrow

Nothing major so far, since the bonding of the back and front clip. Just little bits here and there: Once the bond had dried, Dad removed the front brace bar and replaced the screws in the wings with rivets for extra strength, and holes left behind have been filled with fiberglass paste. He has also painted the rear cross member black for a neater finish as I didn’t want the red showing through the dummy engine.

More work done on the dummy engine. I have built the metal bars for the other side and added Allen bolts for a more authentic look, and the mesh for both sides and the centre have been cut out. I was going to paint the metal bars, but decided to rub them down with wet n dry to get a brushed look which I think looks good. This was more of an accident really as I scratched the metal I was working on, and rubbed the scratch out  and liked the look! So in the end I went the whole hog and rubbed down the whole metal bar. Yesterday I also went to a scrap yard and found 2 BMW maff sensors and an oil cap to place at the rear part (like Rudy did). The wires for the maff sensors I have used from an old scart lead (who uses scart leads these days eh?  ;D). I am going to add just a few more pipes with hose clips and then I think that will be it. Don’t want to go overboard. After that I will take it all apart and start painting it.

Petrol cap is bonded into the housing ready for a trial fit. I am going to do this tomorrow as well as extending the breather pipe (filler pipe extension done). I am going to trail fit the housing first to make sure it opens correctly before bonding on permanently. This is the next major job that needs to get done.

Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on September 02, 2013, 05:13:54 PM
Well done Paul looking forward to the pictures of the dummy engine sounds like its really coming along nicely  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 02, 2013, 09:24:05 PM
Right, managed to borrow my wife's phone for some pictures....

Here is the dummy engine with both brace bars done in metal, with allen bolts and a filler cap at the back of the engine
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130902DummyEngine_zpsb81f78b1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130902DummyEngine_zpsb81f78b1.jpg.html)

This is the underside view. I basically cut away the original plastic diagonal piece and completely replaced it with an metal U-channel (blue arrow) It is bolted to the middle section of the engine underneath it and to the other piece of metal via L-shaped brackets. The long straight piece of metal is L-shaped and fits over the the orignal DNA plastic part (yellow arrow). It will also be bonded when it is finally fitted.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130902DummyEngineUnderneath_zpsc7c5aa21.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130902DummyEngineUnderneath_zpsc7c5aa21.jpg.html) 

Here are the maff sensors I picked up from the local scrap yard yesterday along with the filler cap - all 3 pieces total £5! The wires are a cut down scart lead
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130902Maff_zps40eda824.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130902Maff_zps40eda824.jpg.html)

I plan to work on the car tomorrow and do the fuel pipes et al. Here is a picture of the breather pipe extension. The circled part is the original pipe and bracket that was attached to the car. I just cut a length of around 9 inches or the metal breather pipe and then added the flexible hose.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130902BreatherPipe_zps226e49fe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130902BreatherPipe_zps226e49fe.jpg.html)

Below is the other end of the original metal fuel filler pipe. I haven't trimmed down the breather part as much as in the DNA fitting video as I wanted to see how long the flexible breather pipe is first. Plus I am going to add my earth strap to this part as well.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130902FuelNeck_zps614a670a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130902FuelNeck_zps614a670a.jpg.html)

Here is the mondeo flap bonded into the housing, ready for trial fitting
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130902Flap1_zps00533515.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130902Flap1_zps00533515.jpg.html)

I found the square part of the DNA housing is too deep for the flap I had - so I needed to pack it out to bring it higher. If I didn't the flap would catch the bodywork of the car and stop it from opening.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130902Flap2_zps91ca63c7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130902Flap2_zps91ca63c7.jpg.html)

Also to stop the actual hinge part catching on the bodywork as well, I ground down the edge circled below as much as possible so there was clearance.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130902Flap3_zps475a729a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130902Flap3_zps475a729a.jpg.html)

I am going to trial fit this housing tomorrow using gaffer tape to make sure everything clear's before bonding. Hopefully will get it all permanently fixed on Sunday. Total build time so far 117 hours.

Paul  ;D

Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on September 02, 2013, 10:09:27 PM
Nice work Paul. Brings back a lot of memories.
Keep it up and your dummy engine is looking great.
Title: Re: Paul's 4thirty Build Diary
Post by: Darren on September 02, 2013, 10:56:36 PM
The latest generation of builds are getting a lot of attention in the engine covers, looks like I'll be scrounging round a couple of scrap yards sometime soon ;D
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on September 03, 2013, 12:37:36 PM
Thanks for the pictures Paul very nicely done  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 04, 2013, 12:42:43 PM
worked on car last ngiht - full update later, but for now, question out there for you gurus. Anyone tried to connect the MR2 original petrol flap wire to the mondeo one? Below is a diagram of the 2 pieces.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130904petrolflapcable_zps2da989b7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130904petrolflapcable_zps2da989b7.jpg.html)

If you strip down the original MR2 cable, you are left with a wire and a metal cylinder on the end which is like a bike brake cable end – this would need to be joined to the hole that is in the end of the mondeo release bit. anyone got ideas on how to join the 2 together?

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 05, 2013, 12:53:59 PM
Spoke to Roland - said that the MR2 plunger should work directly with a little sanding down. Cheers Roland. Will try that at the weekend
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 05, 2013, 08:36:23 PM
Total Build Time: 120 Hours

 
So went over Tuesday night to do a few things. For the first half hour I took stock of everything as this was the first time I’d been back since bonding all the bits on. I gave the car a good clean as that black beta seal gets everywhere and had a look around.

Here we have the view from the rear with the cross member painted black. Will look good below the dummy engine I think.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903CrossMember_zpsaa9357bb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903CrossMember_zpsaa9357bb.jpg.html)

Here is the passenger wing showing rivets and the hole filled in with glass fibre paste. When I bonded here all I had was 1 screw into the pillar holding all in place and tons of beta seal underneath it. Once dried, dad replaced the screw with 2 rivets.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903PassTopWing_zps8313a1d0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903PassTopWing_zps8313a1d0.jpg.html)

Below are the bottom of the front wings/sill joins. Wing is bolted and bonded to the sill and the sill is screwed/bolted to the original car. Will give them a clean/tidy up at a later date.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903PassSill_zps3bc723c3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903PassSill_zps3bc723c3.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903DriversSill_zps365c9e80.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903DriversSill_zps365c9e80.jpg.html)

Here is the view with the front brace bar removed.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903BraceBarRemoved_zps9ee3c0d2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903BraceBarRemoved_zps9ee3c0d2.jpg.html)

And below circled is the slimline washer bottle I have installed. I got this along with the pump for £5 from an auto jumble a while back
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903WasherBottle_zps17bf9b81.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903WasherBottle_zps17bf9b81.jpg.html)

So this is what the car looks like now. I’ll have it up on axel stands for the most of the rest of the build. Don’t want to damage the alloys and they do get in the way some times. I have no need to move the car until it is ready to be painted (blimey – that is a way off)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903FullPic_zps3e0ea86e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903FullPic_zps3e0ea86e.jpg.html)

Next was extending the petrol pipes. I had already done the fuel filler, but I now needed to do the breather pipe. This is quite an awkward job to do. I recommend taking out the battery and also jacking the car up as high as you can, as well as removing the protective floor shields that are bolted to the bottom of the car.

Below show the breather pipe back in place. I have circled it accordingly and show what is original MR2 and what is the extended pipe. In this picture you can see both petrol and breather pipes.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903PetrolPipe1_zps400ec5b9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903PetrolPipe1_zps400ec5b9.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903Breather1_zpsc3c40845.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903Breather1_zpsc3c40845.jpg.html)
 

This is just the very bottom of the petrol pipe – this is all original MR2 pieces. For both petrol and breather pipes, I cut off the bottom of the original MR2 pipes and then added my extended hoses onto these. This way the originally joined sections are still there.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903PetrolPipe2_zpsd0c37e7e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903PetrolPipe2_zpsd0c37e7e.jpg.html)

 
Here are the extended pipes poking through. They will need trimming when fitting to the MR2 filler neck. Also note the rubber trimmed I lined the hole with to protect the pipes from scraping on bare metal.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903RubberEdge_zps3a7aa0c4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903RubberEdge_zps3a7aa0c4.jpg.html)

Next I worked on the petrol flap cable. In its current location it is too short to reach the new flap, so I read that it can be re-routed. To do this you need to remove the yellow rocket shaped piece like below, cut off the rubber grommet that is on the car body and then you can feed the wire back inside the car.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903PetrolCableEnd_zps57e47608.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903PetrolCableEnd_zps57e47608.jpg.html)

Then I had to remove both seats, and the folding down glove box doors that go behind the seats and the plastic bases of the gloves boxes  - then you can pull the carpet forward a bit and pull the whole cable out. See below
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903PetrolFlapCable_zps92c1af01.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903PetrolFlapCable_zps92c1af01.jpg.html)
 
I then fed the wire along the rear of the car as if it was going to be inside the rear glove boxes eventually, pulled back the large rubber grommet to allow the cable to go through and poked it through
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903Grommet_zpsf7fe7971.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903Grommet_zpsf7fe7971.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903CableHole_zpsa0bfe074.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903CableHole_zpsa0bfe074.jpg.html)

It is now long enough to reach around the back of the flap nicely.

Next I trail fitted the housing to the car. I stuck blu-tack on to account for the thickness of the beta seal, and then taped it to the car. Seems to clear ok.
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903FlapBluTak_zpsa9d85dfd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903FlapBluTak_zpsa9d85dfd.jpg.html)
(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903FuelFlap_zpsbde29cd7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903FuelFlap_zpsbde29cd7.jpg.html)

Next thing is finishing off the flap. Will do that Sunday hopefully
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 05, 2013, 10:05:12 PM
Going a bit crazy with the updates today  ;D Did a little bit more on engine tonight - Added some hoses with hose clips. This is what it looks like now (don't have the mesh on at the moment)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130905Engine1_zps1c0e4c6e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130905Engine1_zps1c0e4c6e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130905Engine2_zpsf99a81c5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130905Engine2_zpsf99a81c5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130905Engine3_zps68cfa894.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130905Engine3_zps68cfa894.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130905Engine4_zps6a22c8bb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130905Engine4_zps6a22c8bb.jpg.html)

Will probably add a few more hoses and then that will be it. Don't want to go overboard. Then I can get one with painting it all!!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on September 05, 2013, 11:18:51 PM
Great work mate. Coming along nicely.
Title: Re: Paul's 4thirty Build Diary
Post by: kalifornia on September 06, 2013, 11:39:58 PM
Very good updates with pictures.
You are documenting nicely and this will many people all over the world. Well done, keep it coming. Can't wait to see your finished car.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 08, 2013, 01:31:23 PM
Latest pictures of engine. I think I am done now. Added more hoses and cables. Used old TV aerial/co ax cables.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130908Engine4_zps047772da.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130908Engine4_zps047772da.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130908Engine2_zps77077915.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130908Engine2_zps77077915.jpg.html)

Need to do a bit of filling in places where the GRP chipped off, but no more building needed.
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on September 08, 2013, 03:32:14 PM
Looking good Paul and great use for old TV cables!!!  :)
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on September 08, 2013, 06:51:24 PM
Nice job Paul it looks great  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 09, 2013, 08:08:24 PM
Total Build Time: 123 hours

Sunday didn't go quite according to plan. Only managed to get over there for 3 hours in the evening.

Anyway there was some progress. I carried on with the fuel pipes. After my post about the fuel flap plunger issue I looked at what I could do with the MR2 one. Seemed simple enough in theory, however I had already made the hole in the carrier big enough to fit the original mondeo plunger with it's housing and with this removed and the MR2 one in there it looked a little lost in the big hole.

So I had the idea to combine the two pieces. I cut off the end of the Mondeo part, removed the bit that actually moves in and out and glued the housing part back into the carrier.

Then I ground down the MR2 yellow rocket part bit to the right length and then I glued and fibre glass in place on the carrier. Then all that is needed to do is place the actual MR2 plunger end back into the yellow rocket and it should work. Have a look at the pictures. They say a 1000 words! Before I forgot I drilled some holes in the flap for when gluing the lid on.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130908YellowRocket_zps1ba19799.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130908YellowRocket_zps1ba19799.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130908YellowRocket2_zps0a465ede.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130908YellowRocket2_zps0a465ede.jpg.html)

Next I thought about the actual filler neck. I spent ages building a metal bracket to hold the thing in place behind the housing but later ditched the idea as there wasn't enough room and once I had actually attached the hoses I didn't think it would be necessary. I will bond the metal neck to the carrier once installed.

Next I used body filler to fill up and neaten up the housing where the square hinge is contained to bring level with the curved parts of housing. I did this now before gluing the housing to the car as it is easier than doing with it attached to car. If you don't do this then they'll be a gap between the wing panel and where the housing is at this point. You prob wouldn't see the gap with the flap shut and the lid on, but still, that would annoy me.

While that was drying I cut the extended hoses to the right length and hose clipped the fuel filler and breather pipes on.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130908Pipesdone_zpse4afb8f7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130908Pipesdone_zpse4afb8f7.jpg.html)

So then all I had time for was to bond housing to car which I did after checking for flap clearance. Job done. I used betaseal to attach it and then from the inside of the arch I put beta seal around the back of the housing as well. I know people use glass fibre but I had a tube of beta seal that I had cut open so I used it all up on this.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130908FuelHousingStuck_zps756e9fc5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130908FuelHousingStuck_zps756e9fc5.jpg.html)

Dad tells me today it is stuck hard and he has clipped the MR2 plunger back into the yellow rocket and it is opening and closing a treat! So something went right. Hooray. Will work on the next part on saturday
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on September 09, 2013, 09:31:20 PM
Well Done, Paul. You've conquered my arch-nemesis >:(

I still have problems with my fuel flap not opening when I want it to. Never mind these things are meant to try us.

Keep up the great work.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on September 09, 2013, 09:56:46 PM
Looking good Paul keep up the good work buddy.

Your plates will be in post hopefully tomorrow :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 10, 2013, 01:26:01 PM
Cheers Chaps...plenty more work to do on the flap Beany but hope to have it all done at the weekend.. then onto other things!!! probably exhaust!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on September 10, 2013, 03:51:11 PM
Cheers Chaps...plenty more work to do on the flap Beany but hope to have it all done at the weekend.. then onto other things!!! probably exhaust!  ;D

Exhaust is always a fun place to be Paul!  :D
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on September 11, 2013, 04:45:21 PM
just realised I had missed your post about bonding the front end on etc!! Its looking absolutely fantastic!

Just one question...open to the forum really, when you bond to the A pillar, should you use P40 or can you fill and smooth over Sikaflex without it cracking (as it is flexible!!)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 11, 2013, 08:48:52 PM
Phil, I'll tell you what I did in terms of the front clip...brace yourself.... ;D

When it was dry fitted I used 1 screw on the a pillar and then the actual mr2 original bolt hole at the bottom of the a pillar. However when it comes to bonding everything moves slightly and needs adjustment as you said to me before.

So in the end I didn't bother with the mr2 bolt hole. As when I was ready to bond it all, I couldn't get it to work with the bolts so I didn't bother. And to stick it all I used betaseal. Not P40. I don't think P40 is right as it forms a too rigid bond which I think would shatter/be too brittel. So the top of my a pillars are secured with betaseal and now 2 rivets a side. When I was bonding though I did still use screws still (one a side) instead of rivets. I just replaced the screws with rivets once it was all stuck. Betaseal is better as you can secure the top of the a pillar with a screw and beta seal and then squeeze in a load of beta seal further down underneath to fill the gap. If you put in too much it can always be cut away after it has hardened. See photo below:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130903PassTopWingDetail_zps7371beea.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130903PassTopWingDetail_zps7371beea.jpg.html)

I bonded/bolted and screwed the bottom part to the sill first and then did the a pillar part afterwards. As it is here where the adjustment is needed to stop the door catching on the wings. I had Dad to help so I recommend you have someone with you just to hold things like bolts/screws/tools and pass stuff to you. It was quite stressful but ok in the end. Obviously you don't have front bumper on when you do all this.  The holes left behind from when I dry fitted it with the mr2 bolts have been filled with P40.

Brackets that attach to headlight carriers and the front sides of the bumper near the headlight holes, can be done at a later date. I haven't done mine yet.

Good luck and one last thing....before you start put 4 cans of beer in the fridge to chill as you'll want them afterwards. Cheers!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on September 12, 2013, 08:24:16 AM
thanks for the detailed explanation Paul....I am still planning on doing mine this weekend...GULP!!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 14, 2013, 09:33:56 PM
Total Build Time: 131 Hours

Good 8 hours today. Worked on petrol flap and started on the exhaust. First Update: Petrol Flap

Started off by fitting the earth strap to the breather pipe. Used a hose clip and added wire underneath and then soldered it. Scratched off the paint from the breather pipe to bare metal to ensure a good contact first.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Fuel1_zps958f56f0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Fuel1_zps958f56f0.jpg.html)

Once happy, zip-tied it all and covered in insulation tape

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Fuel3_zps3964345c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Fuel3_zps3964345c.jpg.html)

Fed the earth wire through the same hole where the pipes go and into the area where the car battery is. Will Earth to the battery once I put it back in.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Fuel2_zpsb8e71c54.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Fuel2_zpsb8e71c54.jpg.html)

Then the cable for the plunger to release the filler flap I tied up by sticking these zip-tied holders to the inside of the car and then zip tying the plunger cable to these.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Fuel4_zpsf8b1bf41.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Fuel4_zpsf8b1bf41.jpg.html)

Next, started work on the filler flap and surround. It was all stuck last time, so now I wanted to start filling in the gaps etc.. This is what it looked like before:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Fuel5_zpsd96cc472.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Fuel5_zpsd96cc472.jpg.html)

Then started to body fill around the edges

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Fuel6_zpsf51cc8c9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Fuel6_zpsf51cc8c9.jpg.html)

Then rubbed it down. I know it isn't perfect, but I have done the foundations of the work. This would be more difficult if the flap cover was on so I did it first and the body shop can do the rest to get it perfect.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Fuel7_zps3e72d01e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Fuel7_zps3e72d01e.jpg.html)

Then the moment of truth... stuck on the flap and let it stick for a bit. I had run out of BetaSeal so used some Stixall Extreme Power which seems to be similar - got it from ToolStation and was the most expensive stuff they did. I put loads on as I had to pack it out a bit to bring the cover forward slightly.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Fuel8_zps96d9897e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Fuel8_zps96d9897e.jpg.html)

Once that had cured, I opened up the flap and then fibre-glassed over it as well to make it really strong

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Fuel9_zps5df9e288.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Fuel9_zps5df9e288.jpg.html)

Here is the neck in place. It points slightly backwards due to the angle of the fuel filler pipe extension but rather that than a bend in the pipe. Should still work fine at the petrol pumps. In order to hold this in place I planned to foam fill from the inside to hold it and the fibre glass the back of it. Below I have stuck cardboard behind to stop the foam filler going through.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Fuel10_zps054b16bd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Fuel10_zps054b16bd.jpg.html)

Here is the foam filler drying. I decided to leave it to harden as I had run out of time.. Can trim all this off later.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Fuel11_zps68e95a2a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Fuel11_zps68e95a2a.jpg.html)

So finally shut the flap for the day and this is what we have. It certainly isn't perfect but to be honest I dont think I could get it much better. I will see if the body shop can improve on it. I'm not gonna waste time trying to better it.  The gap at the top is a little large, but that was the circle in the wing that Dad cut out. It isnt terrible and hopefully people will be looking at other bits of the car not to notice!  ;D 

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Fuel12_zps0bf6c34b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Fuel12_zps0bf6c34b.jpg.html);D


Exhaust update tomorrow...
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on September 14, 2013, 10:01:17 PM
A big job out of the way there Paul and any final tidying can be done prior to paint. Well done mate, look forward to exhaust update  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 15, 2013, 08:23:55 AM
Part 2: Exhaust Update

Preparation started Friday night. After a long week at work I treated myself with a trip to Halfords to get the right sized clamps. Normally Halfords can be expensive but each clamps was £1.50 and this is cheaper than what I could get elsewhere so went for it.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130913Exhaust2_zpsc9ae8759.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130913Exhaust2_zpsc9ae8759.jpg.html)

This is the exhaust hanger I also bought - again cheaper £3.50

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130913Exhaust4_zps74b3dee7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130913Exhaust4_zps74b3dee7.jpg.html)

These clamps I got off eBay and coupled with a builder's strap I planned to make brackets to support the exhaust further from the bumper bar.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130913Exhaust3_zps1c3df95f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130913Exhaust3_zps1c3df95f.jpg.html)

Finally, bubble wrapped the exhaust tips to protect them when I was trail fitting them.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130913Exhaust1_zpsa06cdec3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130913Exhaust1_zpsa06cdec3.jpg.html)

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 15, 2013, 09:02:51 AM
So onto the fitting. Firstly when I was trial fitting the exhaust previously I noticed that the 2 pieces of metal on the orignal MR2 that stuck out (I think the original wings/lights where attached to them) got in the way of the exhaust. They don't seem to have any structural need so I cut them off. But if I had my time again, I'd defintiely do this before bonding on the rear clip as it was an absolute bugger to cut off with the rear clip on!!!  :(

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Exhaust1_zpscff510b8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Exhaust1_zpscff510b8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Exhaust2_zpsd5e00a3b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Exhaust2_zpsd5e00a3b.jpg.html)

Here's the same on the other side

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Exhaust3_zps222bfddf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Exhaust3_zps222bfddf.jpg.html)

I also cut this nut hole off as it was getting in the way

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Exhaust6_zpsd86c0925.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Exhaust6_zpsd86c0925.jpg.html)

Then I worked on trying to support the driver's side of the exhaust near the sliencer using the hanger I had bought. I bent the bracket first...

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Exhaust4_zps9142751e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Exhaust4_zps9142751e.jpg.html)

...and then attached the hanger to the car body by drilling 2 holes through the wood in the rear clip. HOWEVER... I have since canned this idea as I was worried about heat transfer to the wood/GRP once the exhaust got hot.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Exhaust5_zpsc85ed771.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Exhaust5_zpsc85ed771.jpg.html)

So I decided to work on the passenger side tail pipe alignment. I recommend that when you fit your exhaust, any slots in the pipes, you recut slightly wider and deeper so that when you do the clamps up it really bends the pipe inwards and the clamps actually clamp!  ;D I kept running into problems as the clamps would just not hold so in the end it took the exhaust pipes all off and cut everything deeper... including the slots for the tail pipes. I also had to trim down some of the actual pipes - the L shaped one that goes into the silencer on the passenger side as when fitted it was  a) too wide and b) caused the tail pipe to sit too low.. but that the fun of it!  ;D

Here is the bracket I made that is to be bolted to the bumper bar

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Exhaust8_zps1b7e31b6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Exhaust8_zps1b7e31b6.jpg.html)

And here is it installed

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Exhaust9_zpsf80d920c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Exhaust9_zpsf80d920c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Exhaust10_zps84e78b2c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Exhaust10_zps84e78b2c.jpg.html)

I had fitted the tail pipes and it seemed to be ok, but the top pipe that goes into the silencer still could do with being supported from the top as it was still a bit shaky. So as time was running out and that I wouldn't get a chance to do the other side, I used the exhaust hanger from before and modified it. I undid the metal bracket (the one I had bent previously) and then searched for some where to attach it to that was metal.

As luck would have it, there was a an original MR2 holt with a welded nut that even fitted the exhaust hanger bolt so used that. (above the one I cut off before) This really made my day as it was the perfect place. There is also one on the other side for when I do the drivers side. (It is in used for the heat shield but I can use and extended bolt there)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Exhaust11_zps26957fde.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Exhaust11_zps26957fde.jpg.html)

It is now lovely and secure. I will have to take it all apart again to put exhaust paste on the joints, but the hard work in trail fitting it is done.

And this is the end results. I'm really happy with how the pipes stick out - this was exactly the look I was going for..

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Exhaust12_zpse4031f8f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Exhaust12_zpse4031f8f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Exhaust13_zps75548023.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Exhaust13_zps75548023.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Exhaust14_zps618cc837.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Exhaust14_zps618cc837.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Exhaust15_zps68eed4cb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Exhaust15_zps68eed4cb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130914Exhaust16_zps236fded0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130914Exhaust16_zps236fded0.jpg.html)

Now just gotta get the other one in the same position!!!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on September 15, 2013, 09:11:58 AM
Brilliant write up as usual mate.

Goog work with the exhaust, looks perfect!
Title: Re: Paul's 4thirty Build Diary
Post by: ferrari feb 14 on September 15, 2013, 11:11:10 AM
Hi Paul nice job on the exhaust just a heads up tho remember the exhaust will move with the engine so all the brackets should hav a bit give in them that's why they are always rubber mounted ,I fear the clamp with the metal strap on will cause a vibration and eventually crack ,keep up the gud work ,
Title: Re: Paul's 4thirty Build Diary
Post by: ferrari feb 14 on September 15, 2013, 11:18:01 AM
Try using a small double  threaded exhaust bobbin on the strap to chassis end this should cure it ,these bobbins are fitted to old minis you will get one at halfords hope this helps cheers jd
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on September 15, 2013, 11:20:07 AM
Good work Paul its those fiddly jobs that take time.

Not long and will be ready for paint :)

Your mirror plates were posted sat so should be Tuesday :)

Keep the pics coming
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 15, 2013, 01:22:18 PM
JD, yeah i see what you mean about having the strap all metal and rigid. I have looked at the bobbins and not sure how it would work with what I've built. What I was thinking, is replace part of the metal strap with an exhaust strap - like below - (probably a 3 inch piece ) probably at the end that bolts to the car. They are pretty strong and reasonably rigid but they do have some give in them for vibration.. What do you think?

cheers
Paul



Title: Re: Paul's 4thirty Build Diary
Post by: Darren on September 15, 2013, 01:25:08 PM
or if you can't be arsed to go to a shop (like me)
http://www.ebay.co.uk/itm/RUBBER-MOUNTING-UNIVERSAL-EXHAUST-BOBBIN-M8-THREAD-ANTI-VIBRATION-65mm-IN-LENGTH-/380561612042?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item589b3d5d0a  ;D
D
Title: Re: Paul's 4thirty Build Diary
Post by: ferrari feb 14 on September 15, 2013, 03:20:22 PM
Hi Paul I think a bobbin is the way to go ,like the one dangerous has shown one side of the bobbin bolted through the strap and the other side through the body this will allow u to keep the set up u have,cheers jd hope this helps.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 15, 2013, 04:48:30 PM
Ah yes... I see what you mean now. The only slight problem with that at present is that to attach the strap to the car I am using an existing nut that attaches the bumper bar to the rest of the car. I am piggy backing off that. I didn't drill a new hole especially to mount the strap. Would it matter if I attached the bobbin at the other end?  Between the exhaust clamp and the strap? I can't see much wrong with that? There isn't much room to drill and new hole in the bumper bar - not sure I'd even be able to get a drill in there! 
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 15, 2013, 08:48:42 PM
Took the dummy engine all apart tonight and carefully labelled up the various leads and hoses and put them away.  :(. It looked very sad in its naked state. But then I started painting it tonight.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on September 15, 2013, 09:53:52 PM
Great work Paul and looks like you had a busy and productive week-end!  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 16, 2013, 04:11:45 PM
Total Build Time: 133 Hours

So now was time to paint the dummy engine. After stripping it all down, I body filled in some areas where the GRP had chipped off and then sanded those down.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130915BareEngine_zpsfeafc4b8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130915BareEngine_zpsfeafc4b8.jpg.html)

Then I primed it all in grey primer

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130915EnginePrimed_zpsf8bc7fe5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130915EnginePrimed_zpsf8bc7fe5.jpg.html)

The I masked off the areas that weren't going to be painted black

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130916EngineMasked_zps35a902d9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130916EngineMasked_zps35a902d9.jpg.html)

And then sprayed all in satin black - It said satin black on the can but it looks a bit 'glossy' but anyhow I am really pleased with how it came out

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130916EnginePaintedBlack2_zps7f8e2633.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130916EnginePaintedBlack2_zps7f8e2633.jpg.html)

Then once that was dried I painted by hand the cylinder heads in red. Will give them another coat tonight. For this I just used Hammerite Red paint - smooth

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130916EnginePaintedRed1_zps6c9ddd03.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130916EnginePaintedRed1_zps6c9ddd03.jpg.html)

Title: Re: Paul's 4thirty Build Diary
Post by: crossy on September 16, 2013, 08:08:44 PM
Very nice work Paul and great attention to detail  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 17, 2013, 07:30:27 PM
Cheers Chris. Very pleased with how it came out. Haven't spray painted for years - not since I was a 'boy-racer' with my E30 Beemer, rolling on massive 14s (not)!!!
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on September 17, 2013, 07:32:45 PM
Looks good buddy keep the pics coming.nice when it all comes together you will want to fit it straight after :)

Did you receive plates today ?
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 17, 2013, 07:36:17 PM
Cheers Beems - Once finished it will be packed safely away until at least I have fitted the rear lid. Got the plates today matey, was just about to let you know...  just had a look at them. Look great thanks...
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 17, 2013, 10:04:43 PM
another coat of red and then painted some silver bits as well using silver enamel paint (not easy to tell in the picture - looks similar to the grey primer) Just had to place a couple of hose clips on to see it taking shape  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130917Engine_zps723710ce.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130917Engine_zps723710ce.jpg.html)

waiting now for my 'artist' brushes to turn up so i can do the Ferrari lettering and horsey in silver

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 18, 2013, 09:35:24 PM
Brushes turned up today so started painting the lettering and horse. Used the same silver as before. Very delicate work but patience pays off. I showed my wife after wards and even she says "It looks lovely" so it must be ok  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/201309Engine1_zps14950df1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201309Engine1_zps14950df1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201309Engine2_zpsd98103cd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201309Engine2_zpsd98103cd.jpg.html)

Primed the cap after giving it a file and rub down - this will be silver as well. will probably bottle out of trying to paint the Ferrari word!  :(

(http://i1315.photobucket.com/albums/t597/pjlucas1/201309Engine3_zpsae49b3ab.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201309Engine3_zpsae49b3ab.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on September 19, 2013, 07:34:23 AM
Looking good Paul. You definitely have a steady hand mate!  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on September 19, 2013, 08:30:09 AM
you are gunna be SOOOO lost when the car goes to paint as you will have nothing to do!!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 19, 2013, 09:17:24 AM
haha - always something to do Phil...  ;D but i see what you mean... thing is, I dont have access to car on a daily basis (as it is at Dad's) so it is not like me doing the engine is in place of building the exhaust. Dad isn't doing much without me being there so i figured I might as well get on with the building of something... once the dummy engine is done, I will wrap it up and put it away until i have done the rear deck and then i will trail fit it again and put it away again. Gonna started on the headlights next as they can be built away from the car. going over to work on the car tonight and hopefully finish off the other side of the exhaust as well as the petrol flap. Watch this space...

 

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 20, 2013, 10:14:53 PM
Total Build Time: 137 hours

Friday update. Managed to get about 2.5 hours done last night.

First looked at the fuel filler pipe. The foam filler had gone hard, so I started to trim it back.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130918Filler1_zpsc9ec2030.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130918Filler1_zpsc9ec2030.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130918Filler2_zpsb6984fb0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130918Filler2_zpsb6984fb0.jpg.html)

So this is where we are now. Could do with some more work, but that is for another day. Will clean it up and paint it black probably. I also plan to secure it from behind with p40 as well. The p40 and p38 around the flap also needs a tidy up, but the flap is closing well, not catching and staying shut.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130918Filler3_zps106eacdd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130918Filler3_zps106eacdd.jpg.html)

So, next was the exhaust. More work on the trail fitting. I had bought another exhaust hanger of which I have removed the bracket like before and hung from the other side. I had to space the hanging part with a bolt (see arrow) to avoid the bracket hitting the body work

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130918Clamp_zpsc0251abe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130918Clamp_zpsc0251abe.jpg.html)

Attaching the tail pipe to the bent pipe, I needed to cut down the brackets i had. I had to trim off the metal where the arrows are otherwsie the clamp just wouldn't clamp.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130918Clamp1_zpsa763a95a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130918Clamp1_zpsa763a95a.jpg.html)

Here is the tail pipe attached..

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130918Clamp2_zps5407bbc7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130918Clamp2_zps5407bbc7.jpg.html)

***A word of advice to future builders*** For every join in the exhaust pipes, ensure there are 4 slots cut in the pipes. I know the photo above there is only 2 but I have since cut 2 more. The metal on these pipes is so tough that if you only have 2 slots the clamps just don't clamp. The metal just doesn't bend enough to grip enough. I still have to cut out 6 more slots on my system but that doesn't matter as I am going to take it all apart and seal it and put it back together again but, the 4 slots is essential in my opinion. Make them reasonably long as well so the metal can actually bend when it is clamped. But not too long so they created a hole on the other side.

Next I made another bracket to attach to the bumper bar for the other side. This is made the same as before and to get round my 'flexibility issue' I did the following: The exhaust strap I bought, I cut up into a square and used as a washer and put it between the car body and the thin strap of my bracket. The bobbin idea would have worked but the fixings to the car are wrong as I am piggy-backing off the bumper bar nut. I am not bolting the strap to the car via a new hole. The builders strap I used is flexible enough anyway so there is enough movement I think anyhow.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130918Washer_zps47be9b75.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130918Washer_zps47be9b75.jpg.html)

So managed to get it all lined up on the night, but the passenger side stuck out more than the drivers. So Dad had a play around with it today and managed to get it looking more reasonable. (Bear in mind these are taken from slightly different distances)

Passenger side:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130920LTailpipe_zps00d97ff1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130920LTailpipe_zps00d97ff1.jpg.html)

Driver side:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130920RTailpipe_zps2db865d9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130920RTailpipe_zps2db865d9.jpg.html)

Full view:

(http://i1315.photobucket.com/albums/t597/pjlucas1/bd5a2f8e-46ae-4e59-8cda-cfa2fa2a9741_zps3d370ad8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/bd5a2f8e-46ae-4e59-8cda-cfa2fa2a9741_zps3d370ad8.jpg.html)

Next job is to take it all apart again   :(, cut some more slots and then re-assemble with exhaust paste as well





Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on September 21, 2013, 06:40:53 PM
Wow loving the exhausts nice job Paul dad must be pleased ;)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 21, 2013, 10:27:29 PM
Yep Cheers Ghall. Very pleased with it all. Final dismantle and proper fit tomorrow morning - bright and early!!! Nothing like a bit of angle grinding at 8am on a sunday!!!!  8)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 21, 2013, 10:36:44 PM
Right... I know you are probably sick and tired of these pictures of my dummy engine, but here are some more  ;D

Spent a couple of hours on it today. Now that the painting is all done, I started to re-assemble it all permanently

Glued on the hose clips and attached all the various allen bolts and screws as well at attaching the metal bars etc...

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130921Engine1_zps63dd9987.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130921Engine1_zps63dd9987.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130921Engine2_zpsf0f7d66e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130921Engine2_zpsf0f7d66e.jpg.html)

Added the leads, maff sensors, some hoses etc..

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130921Engine3_zpsf423fd16.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130921Engine3_zpsf423fd16.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130921Engine4_zpsd327b78b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130921Engine4_zpsd327b78b.jpg.html)

The oil cap has been sprayed silver. Came out quite well

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130921Engine5_zpsa1053152.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130921Engine5_zpsa1053152.jpg.html)

I have also attached and bonded the meshes to go underneath. These are drying overnight. Pictures tomorrow hopefully with the rest of the hoses etc...



Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on September 21, 2013, 11:09:20 PM
Nice work. Keep it up.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 22, 2013, 08:33:23 PM
Total Build Time: 144 Hours

So spent 4.5 hours on the car today. Went over just before 7am and started by quietly fitting the earth strap for the petrol hose.

I crimped and soldered a loop connector to the wire and then attached it to the earth connection on the car battery.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Earth1_zps2c4e6657.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Earth1_zps2c4e6657.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Earth2_zpsea719baa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Earth2_zpsea719baa.jpg.html)

Next as I needed to fit something pretty I fitted the rear reflectors. I was looking for some washers and Dad found these old Spanish coins, so for a laugh we thought we’d have a bit of ‘money’ attached to the car. Will bring back memories for some people here  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Washer1_zpsde5cc1cc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Washer1_zpsde5cc1cc.jpg.html)

Here they are in use!!  8)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Washer2_zps3037f90b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Washer2_zps3037f90b.jpg.html)

During the week DNA had contacted me and said they had some more clamps for me so they sent them on. What arrived were 2 more suitable ones for the bumper bar attachment. I had planned to use these in addtion to what I had fabricated, but in the end I removed my clamps and metal strip and used the DNA ones instead  ;D So now the issue of no-flexibility is a thing of the past!

Next I completely dismantled the whole exhaust system reading for final fitting. I also cut out 2 more slots on the pipes that needed it so now every joining pipe has 4 slots which makes clamping easier.

When I was trail fitting, the drivers side pipe from out of the silencer was very close to the car body, so i cut 2 slots in this lip and bent the metal round and painted it. This gave just enough clearance and allowed the whole silencer to sit parallel with the car body. Cuts circled below

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Cut1_zps24cbd835.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Cut1_zps24cbd835.jpg.html)

Here is the gap created

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Cut2_zpsbf979d5f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Cut2_zpsbf979d5f.jpg.html)

I also added a cut off of the exhaust strap I had as a sort of cushion incase a bump made the exhaust bash against the car (arrow below)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Exhasut1_zps8d6abe52.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Exhasut1_zps8d6abe52.jpg.html)

Silencer sitting parallel

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Exhaust2_zpscf787fa5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Exhaust2_zpscf787fa5.jpg.html)

As with everything when you trail fit and then take off and put back, things move slightly, and now the exhaust hanger on the passenger side was getting very close to the car body as well. So I spaced that out with a bolt like on the drivers side (arrow below)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Exhaust3_zps7b81259c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Exhaust3_zps7b81259c.jpg.html)

So then we went through each joint in turn, lining everything up and sealing and built the whole system back up.

Below are arrows showing the new DNA bumper-bar clamps I put on.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Exhaust4_zps4e06e164.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Exhaust4_zps4e06e164.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Exhaust5_zps1940f390.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Exhaust5_zps1940f390.jpg.html)

So this was the end result. The tail pipes are attached but not sealed as they will come off again when I paint the car, but for now I am very pleased with it all. Started the car up to get it warm and get the paste hardening. Checked and made sure no joints were blowing. Note the reflectors in there as well

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Exhaust6_zpsbb97a082.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Exhaust6_zpsbb97a082.jpg.html)

Dad's been left with a list of things to do... P40 the back of fuel filler pipe to make it more secure, tidy up the cut offs for the front brace bar and cut out the panel on the rear part where the dummy engine will lay.









Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 22, 2013, 08:40:53 PM
When I got home I finished assembling the dummy engine. IT'S NOW DONE! You'll be pleased to hear.. Here are the final 5 pictures of it..  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Engine1_zps699b7701.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Engine1_zps699b7701.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Engine2_zps38f81ed1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Engine2_zps38f81ed1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Engine3_zpsc1786893.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Engine3_zpsc1786893.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Engine4_zpsb803fe00.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Engine4_zpsb803fe00.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130922Engine5_zpse7963c64.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130922Engine5_zpse7963c64.jpg.html)

I have really enjoyed this part of the build as was great being creative... Gonna now wrap it all up and put it safely away for a bit...  :-[
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on September 22, 2013, 09:51:07 PM
Beautifully detailed build diary mate. And looks like it's going to be one sweeeeeet riiiiiide

:D

I'd love to detail and engine. Looks like a lot of fun.
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on September 22, 2013, 10:04:16 PM
Looking good mate. Great progress.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 24, 2013, 08:23:27 PM
Well the dummy engine is now safely packed away for a while now  :(

Today is my birthday and it has been one that I have never experienced before. It is sad to report that Dad is in a bad way. On Sunday night he was assaulted by his step-son, where he was pushed to the ground 3 times (the 3rd time falling backwards over a drop of 1m onto a concrete patio) which has resulted in a broken leg. He is 71 years old. He's been in hospital since Sunday night and is doing ok...I've been to see him last night and this afternoon. He'll be in there a while I reckon, and will probably take 4 months before he can walk again. Obviously this means he'll be doing no car work...so the build may slow down a bit (not that is important anyway) as I have lost my right hand man and advisor (for a bit)  but thought I'd let you all know.. he's in good spirits but it has been a shock to us all..
Title: Re: Paul's 4thirty Build Diary
Post by: sundog on September 24, 2013, 08:42:31 PM
Bloody hell pal hope all is ok and everything gies good!! Sorry to hear that but karma gets everyone eventually. Keep strong!
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on September 24, 2013, 08:50:20 PM
Bloody hell Paul sorry to hear that it sounds like an episode off eastenders hope he recovers soon and hope his step son gets whats coming to him soon all the best mate
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on September 24, 2013, 11:04:03 PM
very sad news - violence in all its forms is terrible and NEVER the answer. Dads are important to look after, especially as they get older - they spend a lot of their lives taking care of us brats and more often than not, ask little in return .... hope he has a solid recovery
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on September 25, 2013, 03:04:13 AM
Sad news Paul.

Hope your dad is feeling better soon.

Takes a brave man to push around a 71 year old. >:(

What goes around, mate.

Keep your chin up, i'm sure dad will be back working on the car before you know it.

Wish him a speedy recovery.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on September 25, 2013, 08:33:17 AM
Jeez Paul, I thought my life was bad....just brings it home that there is always someone in a worse position.

Give all our regards to your dad and wish him a speedy recovery, we will all be here waiting for him to be your right hand man again...

Also, think about what you do next in regards to the guilty party, as, in my situation, I saw red and would have liked to "have a word" with them, but being the intelligent people we are, we need to think about the consequences going forward..... as sundog says, karma comes around, it just takes time.

Again, I wish the best to you and all your family...
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on September 25, 2013, 09:39:46 AM
My thoughts are with you Paul, hope your dad makes a speedy and full recovery. Its sad what the world has come to.
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on September 25, 2013, 09:54:14 PM
All the best to your dad buddy and a speedy recovery.makes me angry how people asult older people and we all know why.they think its easy.cant fight back etc



Title: Re: Paul's 4thirty Build Diary
Post by: DNA AUTOMOTIVE on September 26, 2013, 12:14:09 AM
thoughts are with with wish him well from us
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 26, 2013, 09:44:03 AM
thanks everyone for your kind comments and thoughts. He's doing ok. He may be out by the weekend which would be great.. Will keep you updated
thanks
paul
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on September 28, 2013, 05:46:49 PM
Good news is that Dad Came out of hospital Thursday night and is doing well. Thanks again for all your messages of support.

Here are a few pictures of the current state of the build. Rear frame is just laid on the back of the car. That is the next thing to fix. Front bonnet is also just laid out to keep things tidy.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130928Car1_zpsec115761.jpeg) (http://s1315.photobucket.com/user/pjlucas1/media/20130928Car1_zpsec115761.jpeg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130928Car2_zps06766e20.jpeg) (http://s1315.photobucket.com/user/pjlucas1/media/20130928Car2_zps06766e20.jpeg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130928Car3_zps38dd0fc9.jpeg) (http://s1315.photobucket.com/user/pjlucas1/media/20130928Car3_zps38dd0fc9.jpeg.html)

Here's is a walk-around video. Click on image to play

(http://i1315.photobucket.com/albums/t597/pjlucas1/th_20130926DNA430After144Hours_zpse12f7b36.jpg) (http://i1315.photobucket.com/albums/t597/pjlucas1/20130926DNA430After144Hours_zpse12f7b36.mp4)

Title: Re: Paul's 4thirty Build Diary
Post by: Darren on September 28, 2013, 06:23:16 PM
Glad to hear your dad's well enough to return home, and that your build is progressing nicely
D
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on September 28, 2013, 07:52:44 PM
Great news your Dad is back home Paul! Hope he takes things easy for a while though as must have been quite an ordeal. Love the walk round video shot  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 03, 2013, 09:13:09 PM
Total Build Time: 146 Hours

Went over to see how Dad was getting on last night. He’s doing ok and goes back for a check-up tomorrow. Did a few jobs for him and then spent about 2 hours on the car.

Starting mounting the rear frame. Attached the hinges to each side of the frame. I am using M8 nuts and bolts for rear frame and bonnet. These are heavy pieces so need strong bolts. 

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130310Hinge1_zpsc5da0553.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130310Hinge1_zpsc5da0553.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130310Hinge2_zpsc7434af3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130310Hinge2_zpsc7434af3.jpg.html)

On the rear of the car there are marks suggesting where the holes should be drilled. Don’t make the mistake I did and drill these out first. I found that these didn’t line up. Don’t do any drilling until you have attached the hinges to the frame and then have the hinges resting on the packers.

So after filling in the holes I had pre-drilled earlier, I marked it all up and redrilled the holes correctly.

Below is the rear frame in place with M8 bolts and washer in place. As per the DNA video, the frame should be around 62mm from the rear part of the car (see photo)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130310Hinge3_zps0f818539.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130310Hinge3_zps0f818539.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130310Hinge4_zpsf43598a7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130310Hinge4_zpsf43598a7.jpg.html)

I had bought some bolts specially to secured the frame to the car, but I must have had too many beers that nights and I estimated the length a bit too generously!!! I think you need 80mm bolts - I had bought 110mm ones! Doh! Anyway I have ordered the right ones and should be here for the weekend

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130310HingeBolts_zps9a9b0f43.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130310HingeBolts_zps9a9b0f43.jpg.html)

So that was that, I couldn't really do any more on the frame, so I moved onto the cable for the petrol flap. This needed to be tidied up a bit neater inside the car. I had previously posted a photo of the cable, but I needed to take more slack out of the system so it would lay better inside the car as it was too short. So I positioned it and zip tied it to the breather pipe. It still works fine.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130310FlapRelease1_zps5cb719f6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130310FlapRelease1_zps5cb719f6.jpg.html)

I then replaced the large grommet where the wire feeds through into the car and positioned the cable how i think it will go once the rear glove boxes go back.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130310FlapRelease2_zps023bf62c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130310FlapRelease2_zps023bf62c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130310FlapRelease3_zpsd44ae104.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130310FlapRelease3_zpsd44ae104.jpg.html)

Here is the view from inside the car - wire arrowed

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130310FlapRelease4_zpse2e8e294.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130310FlapRelease4_zpse2e8e294.jpg.html)

Next I noticed the car centre console was getting a bit dusty and damaged so I removed it. I don't know what I am doing with it yet (paint, leather, leaving as it) so thought I'd get it out of the way for now.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130310CentreConsoleRemoved_zps83bd38dd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130310CentreConsoleRemoved_zps83bd38dd.jpg.html)

Next I fitted the height adjusters to the rear frame. Thanks to Phil this was easy as I knew I had to grind off part of them to fit in the hole.

Below is the view of the underside of the frame with the top and bottom height adjusters fitted

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130310HeightAdj1_zpsebd78383.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130310HeightAdj1_zpsebd78383.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130310HeightAdj2_zpsfbd3a5e6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130310HeightAdj2_zpsfbd3a5e6.jpg.html)

Finally I put the frame back on the car.

***QUESTION*** Below is a photo of the height adjusters at the front of the frame. SHOULD the roll bar carrier come further back/frame come more forward so more of the height adjuster hits the roll bar carrier frame? See photo below. I have slight movement I believe on the roll bar carrier frame for it to come backwards (I fitted it ages ago - the first piece in fact!), and the frame can always come forwards a bit as well. Please let me know your thoughts...I guess pulling it back enough for the height adjuster to hit the metal fully?

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130310HeightAdj3_zpse82447ab.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130310HeightAdj3_zpse82447ab.jpg.html)

Here is the other side. This one doesn't even touch, but then again the frame can be adjusted I guess via the hinges.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130310HeightAdj4_zps930f85f0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130310HeightAdj4_zps930f85f0.jpg.html)

***Also*** does anyone have a picture of how the boot release handles are mounted inside the car as plan to do this at weekend if I get that far.
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on October 03, 2013, 10:34:02 PM
2 points....
1. dont pull the rollbar carrier frame back to get the stops to fully touch it, as when you put the rollbar carrier cover in place you may find it too close to the front edge of the rear deck!

2. when you fit the catches to the body, the bit that clicks into the catches and mounts on the frame can be adjusted up and down to alter how close the frame and rubber stops are to the metal of the rollbar carrier....this will also alter the high of the rear deck where it lines up with the main body near to the doors  (the bit on the rear deck that sticks out alongside the side of your roof when its up ) dna fit this with about 1/2 gap, i prefer mine to be a minimal gap...its just a matter of getting the rear deck, the catches, the rollbar frame and the rollbar surround all lined up to your liking!

you then can start lining up the pods....but to be honest, these are probably the easiest part as they have so much adjustment available....
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 03, 2013, 10:56:01 PM
Cheers Phil. I want that gap minimal as well as we discussed a while back on ur thread. Yes, there seems to be plenty areas of adjustment available.
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on October 05, 2013, 08:29:43 AM
This photo isn't fantastically clear, but this is where my driver side rear deck release is located. For the passenger side, I used the factory mr2 engine cover release. This allows me to pop both sides of the rear deck from the drivers side of the car.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 05, 2013, 02:11:16 PM
Cheers Beany. Love the way the circle on the diagram matches the colour of your car! Have you got a t handle pull there in the photo? Also the original mr2 rear boot release lever, is that inside the car next to the original petrol flap lever as well? Sorry I should know that but when I bought the car it went straight to dads and I started stripping it so I never actually got a good chance to look round the original mr2
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on October 05, 2013, 02:31:25 PM
Yeah mate, that is the t handle, you can just make out a darker black shape in that pic, which is the picture of the car with bonnet/boot up on the top of the t handle.

Yes, the original engine cover release sits on the floor with the petrol cap release. I had to change the route of the cable, to pass under the drivers seat, in order to get the little extra length I needed to reach the passenger side rear deck catch.

Hope that helps. Sorry the photo was so poor. lol.

Beany  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 05, 2013, 05:52:07 PM
Total Build Time: 151 Hours

More work done on the frame today. My shorter bolts turned up in time so these were put in place straight away (these are 80mm M8 ones)


(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005HingeBolts_zps93b6e86e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005HingeBolts_zps93b6e86e.jpg.html)

Then I fitted the gas rams. Now, I think I have an issue here. They seem very aggressive. With both of them installed the top really flies open and shakes the whole car. They must be too strong. I fitted both, but at present I now only have one connected as this seems a lot more normal.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005GasRams1_zps80b75432.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005GasRams1_zps80b75432.jpg.html)

This is what is printed on mine. Could someone possibly have a look at tell me if these are too aggressive/what they have on theirs? (Maybe I have been given the wrong ones). Cheers.  

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005GasRams2_zps5a2d3586.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005GasRams2_zps5a2d3586.jpg.html)
 


Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on October 05, 2013, 06:07:17 PM
lol!!
I thought exactly the same mate!!

when you get your rear deck weight bonded on...that slows them down to an acceptable level...dont worry about it at the moment....
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 05, 2013, 06:15:35 PM
cheers fella
much appreciated  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 05, 2013, 06:55:53 PM
Next I fitted the lugs for the catches. As per Phil's build, the hole has to be enlarged. I used a half round file to do this.

Before

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005CatchHole1_zps615b514f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005CatchHole1_zps615b514f.jpg.html)

After

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005CatchHole2_zps030702ab.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005CatchHole2_zps030702ab.jpg.html)

With Lug in place

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005CatchHole3_zps0912f8ab.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005CatchHole3_zps0912f8ab.jpg.html)

Next up the catches. These need to be attached to the following mounting brackets with 2 bolts

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005Catch1_zpsb7044d1b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005Catch1_zpsb7044d1b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005Catch2_zps4b1f7621.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005Catch2_zps4b1f7621.jpg.html)

Bolted in place

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005Catch3_zpsd2221d97.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005Catch3_zpsd2221d97.jpg.html)

I noticed that there is no adjustment on these brackets, so when mounting to the car I used a washer to space out the slight slope seen in the photo below

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005Catch4_zpsf6627d9d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005Catch4_zpsf6627d9d.jpg.html)

Bolted in place - used M8 nuts and bolts here

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005Catch5_zpse915ef1b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005Catch5_zpse915ef1b.jpg.html)

With temporary wire in place

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005Catch6_zpsf0bd0e2b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005Catch6_zpsf0bd0e2b.jpg.html)

Both sides done

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005Catch7_zpsa8f7e1e6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005Catch7_zpsa8f7e1e6.jpg.html)

I thought it would be a good idea to drill out a hole for the 3rd brake light wire now before the deck is bonded on, so here it is...

(http://i1315.photobucket.com/albums/t597/pjlucas1/201310053rdBrakeLightHole_zpsdc0cb190.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201310053rdBrakeLightHole_zpsdc0cb190.jpg.html)

So this is where we are with the frame now

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005FrameFinal1_zpsbc62879c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005FrameFinal1_zpsbc62879c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005FrameFinal2_zps4578d075.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005FrameFinal2_zps4578d075.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005FrameFinal3_zpsc0ccc170.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005FrameFinal3_zpsc0ccc170.jpg.html)


Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on October 05, 2013, 07:02:55 PM
Nice work buddy won't be long til in paint shop :)

Nice when it all comes together.all the best to your dad buddy
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 05, 2013, 07:26:21 PM
Finally, also fitted the drivers rear spacer set up today. As I was at Dad's at 7am, I had to do something that didn't create too much noise!  ;D

Here is the bare MR2 rear hub

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005DriversSpacer1_zps1bbb8731.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005DriversSpacer1_zps1bbb8731.jpg.html)

The original hub around the centre will have corroded so this will need smoothing down to get rid of the bumps so that the inner spacer can be fitted around the centre.

I trail fitted the inner spacers using the MR2 wheel nuts. My MR2 had 15 inch wheels up front and 16 on rear (not sure if it is normal?) So I had 6 short wheels nuts, 6 longer ones and 4 locking ones. Didn't fancy using the locking wheel nuts (as per Beany's build), so planned to cut down 2 longer ones.

Below circled is the longer wheel nut. You can see it slightly protrudes the front of the spacer

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005DriversSpacer1a_zpsf117d917.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005DriversSpacer1a_zpsf117d917.jpg.html)

I started cutting/trimming it down but they are tough buggers. As I am a worrier, I thought that maybe for the sake of my sanity I'll just get 2 more MR2 short nuts and be done with it. 

So for now I used 4 of the short ones I had - these are all thread-locked in as well. (excuse the pink carpet but it does save my knees!)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005DriversSpacer2_zps83b050c7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005DriversSpacer2_zps83b050c7.jpg.html)

Then finally I added the outer spacer and secured with the Allen bolts (and Thread-locked of course) When doing this before you start doing up the Allen bolts ensure you can see the holes for EVERY Allen bolt hole. The holes for them might not be cut in exactly the same position all the way round so you may need to rotate the outer spacer to get all 4 sets to line up. Don't just line up one set of 2 and think all the others are fine. I known it sound obvious now but I didn't realise at the time..  ::)

So here is this one done

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005DriversSpacer3_zpsa8ba34e3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005DriversSpacer3_zpsa8ba34e3.jpg.html)

I will repainted it next time maybe for a nice black finish. Dad has painted it previously off the car and they needed rubbing down in places to get them to fit properly again so that is why they look a bit ropey above.


Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 05, 2013, 07:31:05 PM
Nice work buddy won't be long til in paint shop :)

Nice when it all comes together.all the best to your dad buddy

Cheers Beems

Dad is ok, but it will be a while before he is on his knees filling the sills with foam filler!  ;)

I had a treat though... Had to take his supercharged Jag XJR for it's MOT today - it passed!  Just don't tell him I took it up and down the A12 for a blast before dropping it off!  ;D

Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on October 05, 2013, 08:34:30 PM
Great to see more progress Paul.

Don't forget you need to put a piece of rubber in the bottom of the rear deck claw latches. This stops the lock going down too far into a second stage lock.

The rubber that needs to be removed from the underside of the engine glass is perfect, just cut off a short piece and slot it in the space under the open claw of the latch.

I hope that makes sense.

Beany  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 05, 2013, 08:50:46 PM
Cheers.. Yep Brian mentioned this when I picked my kit up. They are both on the 2nd lock at the moment and the frame is nice and solid. If they are only on the 1st lock, wont they be too loose? I know this issue with the 2nd lock is that it means you can't open it one ur own if you have pulls either side as they lock on themselves.  Could they both work on the 2nd lock IF you could open both at same time from the same side of the car like yours? I haven't played around with the height adjusters yet, so maybe that will solve the issue....   ???
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 05, 2013, 09:34:59 PM
Final post of the day (I promise)

I spent 6 hours on the car today but (in my eyes) didn't seem to achieve that much to be honest. I put this down to 2 things. 1) the gas ram's issue, that Phil now assures me is fine, so that's good and 2) my trial fitting of the rear deck…

As I got the rear frame done I naturally had to lay the rear deck on in place to see how it looked. I think mine is quite warped. It rises up at the front and the back of it. And I can't see how I can bond it properly without some packing out on the frame and some frame modifications. 

Once I had fitted the frame I then tried to adjust it. I fitted as per the video mounting the hinges in the middle of each hole etc...But it seemed too low at the rear. Adjusting it caused all sorts of problems. (Maybe it was because I had one gas ram fitted) but raising the rear part up to max, didn't help, and then it caused all my work on the catches to be messed up.  So I completely took everything off and re-fitted it again slowly and managed to get it back to how it was. In fact I managed to get the rear of the frame v close to 62mm on both sides. Better than before, which was nice.

Below is a picture of what I had posted previously with some arrows.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131005FrameFinal-Question_zpsa451e953.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131005FrameFinal-Question_zpsa451e953.jpg.html)
The yellow arrows are where I think the deck hits the frame first and obviously will be bonded. But even if this is done I think it needs bonding at parts where the blue arrows are. These bits are lower and I can’t see even if I raise the frame up right at the back to its highest point the rear most part will still stick up. I am think about packing out it out and then bonding this as well with the magic black stuff.

The other thing is at the front of the deck, where you have the bits that rest just behind the doors where we talk about a gap being left, these are just standing up in the air as far as I can see. Even if the rear desk is all bonded down I can see that these bits are still unruly. The parts of the frame where I have marked with a green arrow, are these meant to be bonded to the deck as well? I would make sense if they are, but I see that there is a massive distance for this to be achieved. I was thinking of having an extra bracket of some sort to bridge the space and then bond.

Did/does anyone else have these issues and can offer me any advice? I really can’t see how slight adjustment of the frame will solve all these issues…. Shame to end the day on a low... but I'm sure a nights kip and all your wise words with help  :-[
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on October 06, 2013, 03:53:52 PM
the fix for the gap where your green arrow is i was told by dna is it to use the thick part of the front clip brace bar that you remove to fill this space with!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 06, 2013, 04:17:27 PM
Aha. That is a piece of wood isn't it? Have you got any pictures you could show me mate? Thanks.
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on October 06, 2013, 06:38:09 PM
found this pic...only one I couild find, but you can see the packing

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/20121020_130742_small_zps712a9ff6.jpg)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 06, 2013, 08:48:11 PM
ah yes, i can see that. that is what I was planning to so. I might extend it forwards as well. . Will let you know how i get on. did you have to do anything like this as you got your side bits near the doors looking really good. so did you do any packing out at the sides and the back as well (blue arrows)?
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on October 07, 2013, 09:46:24 AM
not as yet, I have only "tacked" it on at the moment, as I aim to get the rollbar surround and pods all lined up before I go back and fully bonf the rear deck on...this is in case I realise that I have done something wrong and need to remove it (i.e. my petrol flap!!) so these bits on mine have nothing in them at this time......
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 07, 2013, 12:44:02 PM
Thanks Phil, I've thought about it a lot and know what I going to do now in regards the rear deck.. I'm not gonna plan to bond it on until Dad is back on his feet as somehting like that would be a lot easier with 2 people....plenty else to do though...  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on October 09, 2013, 05:51:17 PM
 ::) lovely job so pleased your dads getting better. enjoyed the video walk round thanks Paul
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 11, 2013, 08:03:53 PM
Called in to see Dad last night and had a look at the car as well. I had been worrying about the rear frame all week but also has some ideas and help from you guys. Anyway, I laid the rear deck on, and it doesn't seem that bad. I think it needs a little packing out at the back and also the side bit as Phil mentioned, but not a lot else.  Hopefully can have a productive day tomorrow.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 12, 2013, 06:23:28 PM
Total Build Time: 157 Hours

Good 6 hours done today. First job was to secure the fuel filler pipe from the inside with P40

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012FuelPipeFixed_zps15a2c83d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012FuelPipeFixed_zps15a2c83d.jpg.html)

Bit messy, but will give it a tidy up later.

Next was to work on cutting away the roof to ensure that the frame did not interfere with it.  Here is the MR2 roof fully up

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012MR2Roof2_zps0646e356.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012MR2Roof2_zps0646e356.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012MR2Roof1_zpsc5c5d885.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012MR2Roof1_zpsc5c5d885.jpg.html)

Next I started to cut out the rear screen. If you have a good sharp Stanley knife it is like a hot knife through butter. If the cutting suddenly gets tougher, take care. It means you are cutting something thicker so be careful to make sure all is well. The circled bits below are string that are just secure with poppers than can be undone that connect the rear shelf.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012MR2Roof3_zps6fb211c5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012MR2Roof3_zps6fb211c5.jpg.html)

Below is the wire than connects to the glass window.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012MR2Roof4_zpsc84c4289.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012MR2Roof4_zpsc84c4289.jpg.html)

The rear shelf bit is secured with these nuts circled, so undo these, remove the material and then replace the nuts.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012MR2Roof5_zps558051d3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012MR2Roof5_zps558051d3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012MR2Roof6_zps32593207.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012MR2Roof6_zps32593207.jpg.html)

Here is the rear shelf that has been removed. It is held in place by a strap with poppers on each end which need undoing.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012MR2Roof8_zps6d2f26cb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012MR2Roof8_zps6d2f26cb.jpg.html)

And here is the view with the shelf removed. The shelf also clips into the below circle prongs. Just pull it up. The arrows points to the wire that connects to the glass window.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012MR2Roof7_zpsc2526503.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012MR2Roof7_zpsc2526503.jpg.html)

The carpet also pulls away. Below I have clipped and sealed off the rear window wire. One day maybe I’ll build a Beany hard top so would possibly look to connect this up again!  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012MR2Roof9_zps83abb539.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012MR2Roof9_zps83abb539.jpg.html)

I also removed the straps below either side (like Phil did – yellow arrow). This strap I don’t think is needed, and when the frame shuts it hits in anyway. The strap is riveted to the bars, I drilled out the rivets and then let the strap just fall. Will not cut it off just yet, just in case. ;D I also have cut away more of the roof (white arrow) as this was creasing up and hitting the rear deck because I had cut it. When the 430 roof is fitting it would all be smooth and not hit the deck.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012MR2Roof10_zps5fd77caa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012MR2Roof10_zps5fd77caa.jpg.html)


Here is what it looks like now. Yellow arrow showing the extra roof I have cut out.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012MR2Roof11_zps5b1bb473.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012MR2Roof11_zps5b1bb473.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012MR2Roof12_zps63dc2d0e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012MR2Roof12_zps63dc2d0e.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on October 12, 2013, 08:28:09 PM
great write up mate!

you are just about to overtake me!!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 12, 2013, 08:31:16 PM
not finished yet! sit tight  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 12, 2013, 08:44:24 PM
Last Saturday I came away worrying a bit about the rear frame, but during the week, after research and help from the forum, today was a chance to lay my concerns to rest. As Phil told me right at the start, if it gets you down, just walk away and come back another day...  ;D

So, looking at things on Thursday night, things weren't as bad as I remembered. The frame didn't need that much work. I started by adjusting the frame again, raising the rear part as far as it would go. I had it locked down in the catches, but the gas rams removed. Previously I had tried to adjust it like this with one gas ram fitted and it just doesn’t work. The gas ram over powers any movement you do, so best to have them out of the picture.

The frame was still 62 mm each side from the end of the car and was opening and closing nicely. My concern previously was the amount of packing out that would needed to be done to secure the deck. The deck I have naturally curves up and the back of the car and front, so I wanted to ensure that this would not cause a bad fit.

On the rear of the frame I added a piece of shelving wall fixing. It is very common, available from B&Q etc... But this will enable me to add beta seal to the top of this and also secure the rear deck very close to the rear of the deck from inside. It took a while to find the optimum length but got there in the end. This way the rear part of the deck will be bonded in 4 places as opposed to just 3 (there is a raised bit of the frame at the back of it that the deck rests on, plus the 2 sides. Balls to it, have a look at the pictures. They tell 1000 words! As this is no further back that the original frame it should not get in the way of the 3rd brake light.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012DeckPacking1_zps126ce44d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012DeckPacking1_zps126ce44d.jpg.html)

Here is the view further back. It is secured with sunken screw bolts

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012DeckPacking2_zps0f299f16.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012DeckPacking2_zps0f299f16.jpg.html)

Here is the view from looking through the 3rd brake light hole. At this point the deck is in perfect position but it is still not touching the white metal. However the beta seal will fill that gap and provide and extra area to seal...

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012DeckPacking3_zps1f49646e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012DeckPacking3_zps1f49646e.jpg.html)

Next with the rear deck on, I found that the passenger side could do with a little packing out along the side. Now I could have tried to adjust the frame bolts etc... But to be honest, I was happy with everything else and it was all working nice so I just thought leave it, and pack out slightly. I could have used loads of beta seal here instead to bridge the gap but I have tons of this metal strip so I packed it out instead

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012DeckPacking4_zps22905a51.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012DeckPacking4_zps22905a51.jpg.html)

Next was the front of the frame. One of my biggest concerns last week was the fact the DNA frame didn’t touch the side parts of the rear deck near the doors. This need to touch so you can control the gap left by them. Phil kindly posted a photo showing packing out using the remains of the front brace bar. I had already chucked this, but I went back to the trusty shelf wall bracket. This is very stiff/sturdy metal, so I packed it out with this. I cut a very small piece like below. Anything longer would cause problems as it would push out the deck too much. Plus don’t extend it forwards past the original frame either as you could run into roof problems.

Here is the cut off

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012DeckPacking5_zps8e13114f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012DeckPacking5_zps8e13114f.jpg.html)

I drilled 2 holes in this and frame and riveted it in place.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012DeckPacking6_zpsfd310ecc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012DeckPacking6_zpsfd310ecc.jpg.html)

Here it is in situ with the deck on. It doesn’t touch but there is enough gap to get a good amount of beta seal in to hold the bugger down!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012DeckPacking7_zps645163ba.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012DeckPacking7_zps645163ba.jpg.html)

Here is the other side (drivers) I had to pack this one out a bit as it would touch the deck too much. Couple of washers helped. Photo is wrong way round.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012DeckPacking8_zpsdeb3e341.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012DeckPacking8_zpsdeb3e341.jpg.html)

Here we had a gap. Just enough…

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012DeckPacking9_zps8785a02b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012DeckPacking9_zps8785a02b.jpg.html)

All the extra metal bits I have installed are now painted satin black and waiting to dry.
 
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on October 12, 2013, 09:09:40 PM
great work mate...this is becoming a very thought about build!!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 12, 2013, 10:42:19 PM
Next I took the opportunity to cut out the slots for the t brackets out of the deck.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012RoofTBracket1_zpseb46f2c4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012RoofTBracket1_zpseb46f2c4.jpg.html)

Here is the t bracket in place

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012RoofTBracket2_zps17d8afe5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012RoofTBracket2_zps17d8afe5.jpg.html)

So this is where we are with the rear deck. I am now happy with how everything lies.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012RearDeck1_zpse01ef6a6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012RearDeck1_zpse01ef6a6.jpg.html)

Having spent enough time on the rear, I thought I'd have a look around the front. Spent the rest of the time fitting the bonnet catch. You need to ensure the frunk is removed to fit the bonnet catch as it would get in the way. I drilled holes in the scuttle. As for the measurements, I don't know if my car is different but DNA said drill 40mm across and 35mm from the top of the scuttle. Well the 40mm is too far across and the bracket would not be centre. The bracket fits the horizontal part of the scuttle perfectly, so I got it centred here and drilled 35mm from the top of the scttle. If it is not right, i'll will let you know.

Here is the bracket in place. I used M8 nuts and bolts again.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012BonnetCatch1_zpsf2efeb59.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012BonnetCatch1_zpsf2efeb59.jpg.html)

And here is the catch attached. Nothing is lined up yet, just bolted in place for now. I have tidied up the excess cable with zip ties.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131012BonnetCatch2_zps9b99a0d2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131012BonnetCatch2_zps9b99a0d2.jpg.html)


Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on October 12, 2013, 10:47:51 PM
Great detail Paul,

I'm starting to wonder what holds my rear deck in place as I didn't do anything like this, simply used beta-seal in the locations recommended by DNA. It seems to do the job.

"One day maybe I’ll build a Beany hard top"

Maybe one day, I will too. Lol.  :P

I just can't seem to find time to get any headway at the moment. Looking back I don't know how I found the time to build my car; I guess the motivation  was there to keep at it every little opportunity I got.

Will have to pull my finger out.

Keep up the great work, Paul.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 13, 2013, 06:53:10 PM
Cheers Beany

I guess in terms of motiviation is it all all about what you have now and what you'll have at the end. Going from nothing to a replica Ferrari 430 is much more motiviating than going from rep a Ferrari 430 to a rep Ferrari 430 with a hardtop, especially one that already has a V6  ;D

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 18, 2013, 09:12:34 PM
Total Build Time: 160 hours

Got 3 hours in last night. Started by tidying up the P40 round the back of filler pipe and painted all black. Also tidied up the catalytic convertor cable with zip ties.

Started on mounting the brackets for the rear deck pods. For future builders you need a lot of M4 nuts, washers and bolts for this part of the build. Bolts need to be various lengths. Big thanks to Phil for his diary photos on this part. Was a big help for me.

Here is the first bracket bolted on.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017RearBrackets1_zps8b5d1db6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017RearBrackets1_zps8b5d1db6.jpg.html)

Then the next. These are all just done up with normal nuts, not Nyloc ones. I figured that as this whole area of the build needs lots of fine tuning adjustment I want to be able to tighten by hand and then when happy with everything tighten properly. You can't tighten by hand the Nyloc nuts.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017RearBrackets2_zpsc73a0548.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017RearBrackets2_zpsc73a0548.jpg.html)

Here are the spring hinges that bolt on next. I bolted the circular holes to the bracket and the ovals will be to the pod.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017RearBrackets3_zps927ec99a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017RearBrackets3_zps927ec99a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017RearBrackets4_zpsa8be4316.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017RearBrackets4_zpsa8be4316.jpg.html)

Bolted

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017RearBrackets5_zps43d3a190.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017RearBrackets5_zps43d3a190.jpg.html)

Next is the pods. One of mine had hole marks so after putting up against the hinge holes they lined up so drilled out. The other side had nothing. But once the 1st was on I just positioned it in the same way. There is tons of adjustment in this area so wasn't too worried about the initial fix to the hinge.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017RearBrackets6_zpscc9cdf12.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017RearBrackets6_zpscc9cdf12.jpg.html)

Again bolted on with M4 nuts and bolts.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017RearBrackets7_zps06be56e6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017RearBrackets7_zps06be56e6.jpg.html)

Other side

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017RearBrackets8_zpsedee1b6f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017RearBrackets8_zpsedee1b6f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017RearBrackets9_zpsf4193a48.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017RearBrackets9_zpsf4193a48.jpg.html)

Next the gold catches to hold the pods when they are folded down underneath the deck with roof up. These need packing out. Mine seemed to need more packing out than most but main thing is they work.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017RearBrackets10_zps622bae46.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017RearBrackets10_zps622bae46.jpg.html)

Gold catches working

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017RearBrackets11_zpsfad4b6f4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017RearBrackets11_zpsfad4b6f4.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017RearBrackets12_zps48accb98.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017RearBrackets12_zps48accb98.jpg.html)

I noticed that IF the hinge that is bolted here is too close (to the rear of car) then your gold catch below needs more packing out. So I moved them forward (see arrows) and then the catch works better. Just a hint for future reference. Maybe I'll need to move them back when deck gets put on but we'll see.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017RearBrackets13_zps16601ca0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017RearBrackets13_zps16601ca0.jpg.html)

So both gold catches now done and are  fully folded underneath. All good and not touching the hood mechanism etc.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017RearBrackets14_zps333faa63.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017RearBrackets14_zps333faa63.jpg.html)

Next I thought about fitting bonnet for weekend and getting stuff ready

Here is underside of bonnet and bolts ready for it. These are M6 I think but very short ones.  The bonnet is not that thick.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017Bonnet1_zpsd0c48af7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017Bonnet1_zpsd0c48af7.jpg.html)

Also drilled holes for bonnet hinges ready for fitting. Will use M8 bolts here.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017Bonnet2_zps8de5cb6f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017Bonnet2_zps8de5cb6f.jpg.html)

Here is bonnet catch all painted up.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017BonnetCatch_zps3085c5b4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017BonnetCatch_zps3085c5b4.jpg.html)

Here is driver's rear spacer painted up.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131017RearDriverSpacer_zps33594e59.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131017RearDriverSpacer_zps33594e59.jpg.html)

Finished by touching up in black all the metal I added to the frame last week.

Tomorrow I hope to fit front bonnet among other things.

Take care all.
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on October 18, 2013, 09:27:43 PM
great write up again mate!

Yea...my gold catches need to be padded out a bit more as they are not catching properly last time I tried them...

You had to go and show the drivers rear spacer didnt you! you having a go at me cos mine fell off? ;-)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 18, 2013, 09:48:55 PM
Haha. Sorry Phil. That wasn't intentional.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on October 18, 2013, 10:28:38 PM
Beautiful work and awesome hobby!

Phil - your hub story has been shared (and amplified) many times since you told us - My mates laughed heartily and added various humorous inclusions to your tale of woe but everyone is sincerely happy it didn't end badly.

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 19, 2013, 05:20:15 PM
Total Build Time: 166 hours

6 hours done today. Here is the first of a few updates tonight: Following on from Thursday night, here is the fuel pipe/carrier all painted in black.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019FuelCarrierPainted_zpsdb8d5887.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019FuelCarrierPainted_zpsdb8d5887.jpg.html)

Then I noticed that for the external ariel, where I had cut the wires, I had forgotten to tape it all off neatly. It was a bit awkward to do so from inside the wheel arch, so I had a look in from the inside of the car. I worked out that this grommet held the wire, so pulled it out.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019ArielWire3_zps8197dd5b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019ArielWire3_zps8197dd5b.jpg.html)

I thought about completely removing the wire, but then noticed it was connected to loads of other wires, so thought I'd just leave it.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019ArielWire1_zps53e5af43.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019ArielWire1_zps53e5af43.jpg.html)

Now taped up and back in place.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019ArielWire2_zps1e6aa59a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019ArielWire2_zps1e6aa59a.jpg.html)

Next I planned to use the original rear boot pull cable for one of the rear deck hatches (Beany style), I removed the original cable from it's place and fed it back into the car and zip-tied for later.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019RearDeckCatch_zpsa9097054.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019RearDeckCatch_zpsa9097054.jpg.html)

Next fitted the rear passenger spacers. As per my previous thread I used all short MR2 nuts. I had ordered 2 more short ones as I didn't fancy cutting down the longer ones. Got them off eBay for £5 including postage.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019RearSpacer1_zpsdc25a0e1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019RearSpacer1_zpsdc25a0e1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019RearSpacer2_zps6714c8b0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019RearSpacer2_zps6714c8b0.jpg.html)

Then painted Satin black

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019RearSpacer3_zps566c4a28.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019RearSpacer3_zps566c4a28.jpg.html)

More later...

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 19, 2013, 06:48:00 PM
3rd brake light

I thought it be best to try this now before I bonded the rear deck on in case it needed a lot of work, and I planned to add some brackets for it, which I new would be easier to fit without it bonded on

Here is the initial fit

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019BrakeLight1_zps9d990a15.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019BrakeLight1_zps9d990a15.jpg.html)

Not bad. Mine has these lip parts at each end

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019BrakeLight2_zpse5db3568.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019BrakeLight2_zpse5db3568.jpg.html)

After a bit of filing down the inside edge I got it sitting how I wanted

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019BrakeLight3_zpsa5399552.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019BrakeLight3_zpsa5399552.jpg.html)

Here you can see the edge where I filed it down

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019BrakeLight4_zps362fd1c2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019BrakeLight4_zps362fd1c2.jpg.html)

With the rear deck upside down and viewed from inside

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019BrakeLight5_zps90826c02.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019BrakeLight5_zps90826c02.jpg.html)

Here is one of the bracket I made from a trimmed down mending plate, and bent slightly.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019BrakeLight7_zps6542172e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019BrakeLight7_zps6542172e.jpg.html)

All the pieces

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019BrakeLight8_zps131cdfe6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019BrakeLight8_zps131cdfe6.jpg.html)

Here the brackets in place, bonded with some black stuff

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019BrakeLight9_zps1d3d33b7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019BrakeLight9_zps1d3d33b7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019BrakeLight10_zpsd8d43fb1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019BrakeLight10_zpsd8d43fb1.jpg.html)

Finally once dried (ish), I removed the brake light. Job done

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019BrakeLight11_zps1f22bd72.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019BrakeLight11_zps1f22bd72.jpg.html)

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 19, 2013, 08:13:06 PM
Frunk Fitting

In order to get the 'Frunk' to fit properly it needs to be trimmed in places. The main place is where the bonnet catch sits. I thought it best to do the fitting of the frunk first, before I have the bonnet on as I would have easier access.

Here is the frunk untouched. The bolts in the top right corner are where I have decided to mount the alarm siren, thus enabling me to have full use of the frunk. The circled bit is what needs trimming off initially.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Frunk1_zps76310e41.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Frunk1_zps76310e41.jpg.html)

Here we have the top part trimmed off.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Frunk2_zps0d601c2a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Frunk2_zps0d601c2a.jpg.html)

I then put the frunk back in the car to see exactly where the bonnect catch was hitting it

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Frunk3_zps9301546c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Frunk3_zps9301546c.jpg.html)

Next here is the cut out to allow the bonnet catch to fit nicely. I may have gone a bit too generous here, but gave me room for a lot of adjustment.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Frunk4_zps8df53738.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Frunk4_zps8df53738.jpg.html)

Next, I also took the opportunity to trim down the right bottom corner as this bit has to be forced under the inside edge of the DNA wing. (When you do it, you'll see what I mean. It is still a squeeze but this trimming helps)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Frunk5_zpsfd69d789.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Frunk5_zpsfd69d789.jpg.html)

Frunk back in after giving underneath a nice clean up. All bolted down. Bonnet catch has lots of room for adjustment.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Frunk6_zps2116b93f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Frunk6_zps2116b93f.jpg.html)

Tidied up the alarm siren wire

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Frunk7_zpsd5022abd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Frunk7_zpsd5022abd.jpg.html)

Also added back the slim-line washer bottle and tidied up the wiring. The slimline bottle bolts to the frunk as well.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019WasherBottle_zps95a60746.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019WasherBottle_zps95a60746.jpg.html)



Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 19, 2013, 09:10:51 PM
Trail Fit of the Bonnet

So on to the main event - bonnet fitting. I knew this was gonna be a harder part of the build what with all the trail and error involved. So here goes...

As I was fitting this on my own I thought the best approach would be to bolt the hinges to the bonnet first and then bolt the bonnet/hinges to the car.

Here are the hinges being bolted. I changed the bolts used as per a previous update for slightly longer ones to account for a washer and the thickness of the hinge. The bolt used furthest away from the front of the bonnet is slightly longer, hence the 2 washers here

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Bonnet1_zps99e44956.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Bonnet1_zps99e44956.jpg.html)

Hinges fitted

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Bonnet2_zpsd1faf25a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Bonnet2_zpsd1faf25a.jpg.html)

Next, I had already pre-drilled the holes in the car wings. Now, I must confess, this was all down to guess work. There were no pre-defined holes on my wings. I looked at photos of other builds, videos etc.. and tried to guess how the hinges would go. My theory was there is no way you could guess with the hinges bolted to the bonnet and the bonnet held up on the car, so I just went for it, figuring that there is plenty of room for adjustment so would hopefully be okay.

Next, as I was on my own, I had to somehow get the bonnet in a position on the car so I could at least bolt the hinges to the wings. I came up with the below idea of having a wooden plank resting in the frunk to support the bonnet in a position to at least get at the hinges and bolt them through the holes. Note I am using M8 nuts and bolts here.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Bonnet3_zpse65ce045.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Bonnet3_zpse65ce045.jpg.html)

Access to do the bolts up nearest the windscreen was hindered at first. Upon inspection it turned out to the be the original MR2 bonnet stops - see circle in picture below (sorry it may be a bit unclear)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Bonnet4_zps5b78c53f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Bonnet4_zps5b78c53f.jpg.html)

If you remove these you can get to the bolts much more easily. I might even use the bonnet stops elsewhere.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Bonnet5_zps12485e28.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Bonnet5_zps12485e28.jpg.html)

Now for the rest of the time on the car today was spent mostly on the bonnet catch. I found that how I had it originally, even with the adjustment in the bracket available it needed to come over further towards the passenger side, plus it also needed packing out. See the photo below..

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Bonnet6_zps0492e8dc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Bonnet6_zps0492e8dc.jpg.html)

I was getting there, but I finally decided that the bracket on the bonnet catch was just sitting too high. So I re-drilled holes in the scuttle and lowered it down.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Bonnet7_zpsd1e95a8b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Bonnet7_zpsd1e95a8b.jpg.html)

As I was getting there with the bonnet catch alignment I turned my attention to the bonnet fitting. Here the hinges on the passenger side were making it sit too high, especially at the front. In the end I decided to re-drill the lower passenger bolt hole (one furthest to the front of the car) so that the hinge sat in it's lowest position possible.

If I were to do this again from scratch I would make sure that both bolt holes that go at the front of the car are drilled in such a way that the black rubber end bit sits as low as possible - right on the body work. See arrow below. These are the very front bits of the hinge. When you do it you'll know what I mean (Hope this helps you out Phil)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Bonnet10_zps0118a237.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Bonnet10_zps0118a237.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Bonnet11_zps123ced8e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Bonnet11_zps123ced8e.jpg.html)

Bonnet fitting still wasn't great so I had the idea to loosen all the nuts that holds the bonnet to the hinges so they can move freely and then get at least the bonnet sitting correctly when closed, thus meaning at least your bonnet catch and and hinges bolted to the wings are right. Once you are happy with that you know then it is just a case of getting the right positions for your bolts actually into the bonnet itself. This again will be a lot of trail and error again, but if you can get 2 bolts right (one each side) you'll be nearly there!  ;D Me? I'm not there yet as I run out of time!  :(

Here is the bonnet shut though so getting there...All I need to do is adjust and get right the actually bonnet bolts.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Bonnet13_zpsbcba1298.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Bonnet13_zpsbcba1298.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Bonnet12_zps40f69af1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Bonnet12_zps40f69af1.jpg.html)

However in the back of my mind is the fact that the car may not be actually sitting level on the ground. It is up on axel stands at the moment and the ground in the car port is not 100% flat. Maybe this wouldn't really matter but my plan is to get all 4 wheels back on the car next, take it out and get it on level ground and then work on getting the bonnet 100%. Will be nice to see it sitting on all 4 Ferrari wheels as I haven't seen this yet...

Finally  - it has been a month since Dad's accident and today was the 1st time he was able to come out to see the car. Today he was a big help with the bonnet alignment side of things. It is just nice to have someone to discuss things with. Good to have my right-hand man back. (might need to put some alloys on that zimmer though!)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131019Dad_zpsf23f13da.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131019Dad_zpsf23f13da.jpg.html)












Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on October 19, 2013, 11:14:35 PM
laid in bed with my tablet and though I must see what paul has been up to...mate yet again a very helpfull write up! I will be re reading this when I get to my bonnet fitting!

great to see ur dad looking well!
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on October 20, 2013, 09:11:55 AM
Great to see your dad back at it with you Paul.

I remember the long hours spent fitting the bonnet. Like you say, a lot of trial and error, slackening and tightening bolts etc. I think I even shimmed my hinges at one point.

Keep tinkering and it'll get there in the end, and you'll breathe a huge sigh of relief, lol.

Great update with useful info for other builders. I can't remember if I've said before, but you and Phil building at the same time reminds me of when Beems and I were building our 430's, bouncing ideas off each other. It's really helpful at times.

Keep up the great work.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on October 20, 2013, 09:56:20 AM
Great work. Brings back many memories.
When I read your build I keep on saying, oh yes I remember doing that bit.
It will not be long mate when you will be saying the same things.
Enjoy these moments, they are the best part of the build. Very satisfying.
Great to see your Dad back in the garage with you.
Keep smiling  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 21, 2013, 10:34:01 AM
Great to see your dad back at it with you Paul.

I remember the long hours spent fitting the bonnet. Like you say, a lot of trial and error, slackening and tightening bolts etc. I think I even shimmed my hinges at one point.

Keep tinkering and it'll get there in the end, and you'll breathe a huge sigh of relief, lol.

Great update with useful info for other builders. I can't remember if I've said before, but you and Phil building at the same time reminds me of when Beems and I were building our 430's, bouncing ideas off each other. It's really helpful at times.

Keep up the great work.

Beany ;D

Yeah I have thought that it seems history is repeating itself with this new duo!!!  Rudy was just too fast!  ;D. I have just re-read your build dairy Beany and have just started reading Beem's again as well. It is amazing how much help they are. I had already read them both twice each, but each time you pick up lots of different hints and tips. You notice different things in the diaries depending on what stage your own actual project is at... Will be exciting to get all 4 wheels on at the weekend!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 25, 2013, 10:10:04 PM
Question guys, been looking through my bits and bobs, and come across these brackets. Does anyone know what these are for?


(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025Brackets_zps69c007b1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025Brackets_zps69c007b1.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on October 25, 2013, 10:40:42 PM
Those brackets are your complimentary testicle-flickers

What you do is: when you become totally frustrated with your build you get a trusted loved one to flick your scrote repeatedly until the pain is intolerable.

Then you return to the build grateful that the level of pain doing that is far less than the alternative.

Quite thoughtful I think you'll agree

:D

And of course at the end of the total process you end up with a lovely glowing red set of


wheels

:D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 25, 2013, 11:00:38 PM
errrr thanks Steve. I had no idea. DNA really do think of everything I guess!  :o
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on October 26, 2013, 11:16:10 AM
I believe these are part of the headlight fixings, I'll find you a pic this evening.

They sit between the brackets that fix on the end of the front bumper bar/inner wing, and the headlight ramp.

Pic will explain, if I remember rightly that is, lol.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 26, 2013, 05:44:18 PM
Total Build Time: 176 Hours

Spent a total of 10 hours on the car this week. I have a few updates for you all and to help future builders I will do it in stages a thing at a time... Main things I have done since the last update is:

Fitted...

1) All 4 Ferrari wheels
2) Anderson Clamp
3) Front Wing Headlamp Holder Brackets
4) More adjustment on the Rear Deck
5) Rear Alarm Trigger
6) Took car out of garage to take some photos and do a video  ;D

Stay tuned!!  ;D
 
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on October 26, 2013, 06:32:44 PM
.....I hate you... ;D
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on October 26, 2013, 07:48:04 PM
.....I hate you... ;D
You should get yourself one of these Phill ;D
MADMAN ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on October 26, 2013, 07:55:27 PM
know anyone who has a spare one, with say a wheel hanging off?  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 26, 2013, 08:08:59 PM
Rear Number Plate

Instead of just having a bare number plate attached via hinges on the rear bumper covering the access hole, I wanted to have a surround as well. I have never liked the after market surrounds as I think they are too big/thick around the edges and wanted something a little more understated. I always liked the one on my merc so I rang them to see if they sold them. Yes they did and they were £1.69 + VAT each. Bargain I thought, so I got 2. So here we go...

Here is the surround

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025NumberPlate1_zps6d7d2c12.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025NumberPlate1_zps6d7d2c12.jpg.html)

Butt hinges to bond to it

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025NumberPlate2_zps6e166b4f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025NumberPlate2_zps6e166b4f.jpg.html)

Bonded

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025NumberPlate3_zps6a9d9364.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025NumberPlate3_zps6a9d9364.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025NumberPlate4_zpsdef9bc36.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025NumberPlate4_zpsdef9bc36.jpg.html)

Using countersunk Allen headed bolts. I had a nut on the other side to pack it out a bit as the rear bumper is concaved slightly

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025NumberPlate5_zpsb300f6f2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025NumberPlate5_zpsb300f6f2.jpg.html)

Holes made - I only did 1 each side but made them bigger so I could adjust the surround

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025NumberPlate6_zps00347ba7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025NumberPlate6_zps00347ba7.jpg.html)

Fitted

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025NumberPlate7_zps49853e37.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025NumberPlate7_zps49853e37.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025NumberPlate8_zps676744f5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025NumberPlate8_zps676744f5.jpg.html)

From the inside. The bolts I used were quite long. I may change them, but this was all I had at the time

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025NumberPlate9_zps35f8f846.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025NumberPlate9_zps35f8f846.jpg.html)

Open - it stays open on it own nicely (will probably change once a plate is fitted). Once fitted finally I Will put some magnets on the bottom part to hold it closed flat.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025NumberPlate10_zpse8aa6e00.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025NumberPlate10_zpse8aa6e00.jpg.html)



Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 26, 2013, 08:28:58 PM
I did some more work on the rear deck fitting on Thurs night.

If you want to make your roll bar bracket move forward ever so slightly, you can cut this lip off slightly which will allow you to push it forward ever so slightly

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025RollBar1_zps1ff0eefe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025RollBar1_zps1ff0eefe.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025RollBar3_zpsd14afb65.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025RollBar3_zpsd14afb65.jpg.html)

Here is the roll bar bracket fitted. Yellow arrow points to where I have just cut, Green arrow there should be a MR2 bolt you put in here, as well as a nut on the thread just above the yellow arrow. I also put a nut and bolt (with large washers) at the blue arrow. Have the bolt head under neath so the thread pokes through the top so it doesn't protude underneath too much and get in the way of the seat belt cover that you'll put back eventually.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025RollBar4_zps494b6e69.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025RollBar4_zps494b6e69.jpg.html)

I also drilled a hole each end of the back of the bracket, so I can tech screw the cover to it if need be.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025RollBar5_zpseb3e8d58.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025RollBar5_zpseb3e8d58.jpg.html)

Hole in the cover

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025RollBar6_zpsc2761766.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025RollBar6_zpsc2761766.jpg.html)

I put a screw through for the passenger side, but it didn't need it on the other. Upon reflection now the cover is fitted (it also bolts each side further down - see pictures below) I don't think either is needed, but we'll see..

This is the state of fitting Thurs night - getting there..

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025ReckDeck1_zpsdf9c6826.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025ReckDeck1_zpsdf9c6826.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025ReckDeck2_zps6e25fd10.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025ReckDeck2_zps6e25fd10.jpg.html)

Here is another area where you bolt the roll bar cover to the car. M6 bolt and washer I think. Also see the washer and thread pro-truding through higher in the picture. This is what I was talking about earlier with the bracket fixing

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025ReckDeck3_zps0396a04b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025ReckDeck3_zps0396a04b.jpg.html)

I'm pretty happy with things, but it is difficult to do more without bonding the rear deck on properly as it is this part that drives the lining up of the rest of it... Pod flaps have loads of adjustment available. Worked on them, but think the deck needs bonding before anymore progress can really be made

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025ReckDeck4_zpsabf07901.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025ReckDeck4_zpsabf07901.jpg.html)


Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 26, 2013, 09:50:20 PM
Anderson Plug Battery Charging Point

As with many builders, I wanted to fit an Anderson Plug so when the car is in the garage I can trickle charge it without having to open up the whole rear deck to get to the battery. As I needed a lot of wire for this,  I bought a set of heavy duty jump leads and cut the plugs off. I think you'll need over 2m of cable to run wires from the battery to behind the rear number plate. I had 3m leads and I had to cut them down a bit, but def think 2m would be too short.

Thursday night I measured up the length I'd need and planned the basic wiring route. I planned to run it underneath the rear of the exhaust silencer access hole (the bit you need to put a cover on to mount the dummy engine) and then down the back of the rear clip (near the rear access hole) and then onto the bumper bar - so keeping well away from the exhaust system.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025AndersonClamp1_zps54d61b3f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025AndersonClamp1_zps54d61b3f.jpg.html)

The Friday night I got my mate Ray who's an electrician to crimp the connectors on. On one end we have Halfords battery connectors and the other end the Anderson plug ones. I went for the 175 AMP Anderson Plug (the bigger one) and the lugs on these are massive. Really thick steel. So you need a proper heavy duty, rachet crimper to do these. (Or you could solder the wires into them instead)

Halfords connectors - with heatshrink

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025AndersonClamp2_zpsba5bd8b3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025AndersonClamp2_zpsba5bd8b3.jpg.html)

Anderson Plug connectors - didn't have heat shrink big enough! so taped instead. Very pleased with Ray's work!!! Top quality.
The wire on the leads is no way as thick at the lug holes, but Ray would have doubled up and bent over the wire to pack it out insdie the lug. The cable is fine though, Amp wise. These could jump start a truck, (or even a Beany V6  ;D   - not sure about a Dangerous V8 though  ::) )

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025AndersonClamp3_zps90163cf1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025AndersonClamp3_zps90163cf1.jpg.html)

Here is the Anderson plug clamp that the lugs slide into

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025AndersonClamp4_zpscf2b4e6d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025AndersonClamp4_zpscf2b4e6d.jpg.html)

Here are the wires connected to the battery

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025AndersonClamp5_zpsf82e80d5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025AndersonClamp5_zpsf82e80d5.jpg.html)

I then trailed the wires along underneath the rear clip part. I secured the wires to the underside of the rear clip via zip ties sitting on tie trees.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025AndersonClamp6_zps41ba26fb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025AndersonClamp6_zps41ba26fb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025AndersonClamp7_zps77365c6e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025AndersonClamp7_zps77365c6e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025AndersonClamp8_zps8ddbe305.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025AndersonClamp8_zps8ddbe305.jpg.html)

Next the mounting of the actual plug (as it was only 7am  ;D) I couldn't make noise and drill, and I always try to utilise holes/moutning points that are already there. I noticed on the rear bumper bar this hole that had a thread in it. So decided to use this.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025AndersonClamp9_zpsbe0226d3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025AndersonClamp9_zpsbe0226d3.jpg.html)

So decided to mount it here. I put a washer on a bolt (M6 I think and then threaded the bolt through the hole in the clamp that is the centre of the clamp (there are 2 holes in the clamp but I only think you need to use 1 hole to mount). I put a hard plastic thick washer on the other side to space out and then screwed into the MR2 hole. Job done.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025AndersonClamp11_zps2a2a90d0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025AndersonClamp11_zps2a2a90d0.jpg.html)

I put the positive terminal cover back on the battery after cutting out a little groove to account for the Halfords connector now being there.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025AndersonClamp12_zpsbeb9fd8f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025AndersonClamp12_zpsbeb9fd8f.jpg.html)






 



Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 26, 2013, 10:01:48 PM
.....I hate you... ;D

Oh matey. You'll catch me up soon enough.  ;)
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on October 26, 2013, 10:07:30 PM
Updated my last post above with the photo of the bracket.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 26, 2013, 10:24:00 PM
Thanks Matey. Crystal clear now.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 27, 2013, 08:31:41 AM
Rear Alarm Trigger

The original position of the rear alarm trigger and it's bracket is shown below with the yellow circle. The yellow arrow is the wire

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026RearAlarmTrigger1_zpsf9c97990.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026RearAlarmTrigger1_zpsf9c97990.jpg.html)

The wire is clipped under neath to the car at the back of the battery. I removed this clip to free up more of the wire.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026RearAlarmTrigger2_zpsdeb92c90.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026RearAlarmTrigger2_zpsdeb92c90.jpg.html)

I found that the largest, flattest part of the rear deck where the trigger could touch would be on the side part of the frame. So I planned to attach it to the car here using the original bracket and mounting hole. There is plenty of room inside the rear wing.

The bracket has a lip on it, that I cut off and filed down

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026RearAlarmTrigger3_zpsce5f71a0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026RearAlarmTrigger3_zpsce5f71a0.jpg.html)

Trigger installed

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026RearAlarmTrigger4_zps91f05a73.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026RearAlarmTrigger4_zps91f05a73.jpg.html)

A bit of trail and error with the rear frame closed and I managed to mark out where to drill the mounting hole

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026RearAlarmTrigger5_zpsee3ce59a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026RearAlarmTrigger5_zpsee3ce59a.jpg.html)

With the bracket now mounted, this is the view from inside. The yellow arrow is the bolt to mount the trigger bracket. The red arrow is the back of the fuel filler DNA housing and the green arrow is my temporary catch pulls

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026RearAlarmTrigger6_zps11da14a4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026RearAlarmTrigger6_zps11da14a4.jpg.html)

Mounted

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026RearAlarmTrigger7_zps710338cc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026RearAlarmTrigger7_zps710338cc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026RearAlarmTrigger8_zpsf4729125.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026RearAlarmTrigger8_zpsf4729125.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026RearAlarmTrigger9_zps97a9f07b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026RearAlarmTrigger9_zps97a9f07b.jpg.html)


Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 27, 2013, 10:35:32 AM
Front Headlamp Carrier Brackets to Wings

Fitting these is fairly straight forward, however there were a couple of bump stops along the way.

First of all I trail fitted the brackets to see how they would sit on the inside lip of the front wings. One thing that was apparent from the start is the return lip on the front bumper (as it was fitted) was too large and stopped the brackets reaching the actual lip on the wings

Here you can see the yellow arrows point to the bumper lip

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025FrontBrackets1_zps51fc7c26.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025FrontBrackets1_zps51fc7c26.jpg.html)

So the only way to do this was to take the front bumper off and trim away some of that bumper lip. I marked up the areas that I needed to cut away and removed the front bumper.

Then I trailed fitted the brackets without the bumper on

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025FrontBrackets2_zpsa29bbbf4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025FrontBrackets2_zpsa29bbbf4.jpg.html)

I used M8 nuts and bolts here. Please note, these will not fit all the same way. For some you'll need to put the bracket on the top of the headlamp carrier hole, for others, fit beneath it, you also may need to pack it out. This doesn't matter as ever car is different, and it will also depend on how your headlamp carrier was bolted to the car etc...

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025FrontBrackets3_zpsfb8f05d1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025FrontBrackets3_zpsfb8f05d1.jpg.html)

Below is the areas where I marked out to cut away from the bumper

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025FrontBrackets4_zps4af31c51.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025FrontBrackets4_zps4af31c51.jpg.html)

Cut away parts. I left room either end just in case. It doesn't matter and this bit is not seen at all.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025FrontBrackets5_zps99566537.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025FrontBrackets5_zps99566537.jpg.html)

Then I put bumper bakc on to check for clearance. When I was happy I bolted the bumper up again and then begain permanetly fixing the brackets. It is just a simple case of fit the bracket with the bolt loosely, add some bond to the wing lips, press down the bracket into the bond and clamp and do up the bolts. I put a piece of wood at the bottom part of the clamp to proect the fibreglass of the bumper

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025FrontBrackets7_zpsfc41f00f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025FrontBrackets7_zpsfc41f00f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025FrontBrackets8_zps294deec4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025FrontBrackets8_zps294deec4.jpg.html)

Other side

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025FrontBrackets9_zpsb09ede70.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025FrontBrackets9_zpsb09ede70.jpg.html)

Just thinking ahead here, in the photo below, the red metal where the arrow points to.. (i guess this was orignal arch mounting brackets) does this get in the way of the headlamps? Would it be best to trim it away? Is it needed for the 430? Thanks..

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025FrontBrackets10_zps637d6258.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025FrontBrackets10_zps637d6258.jpg.html)

Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on October 27, 2013, 03:50:05 PM
Looking forward to the video Paul your doing a really good job and its great seeing how many hours you spend on each step  ;D keep up the great work pal
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on October 27, 2013, 05:17:00 PM
know anyone who has a spare one, with say a wheel hanging off?  ;D
             Not any more, sold it ;) ;)
MADMAN ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 27, 2013, 07:47:59 PM
Scuttle Cover

Next I had a look in the shed and found the scuttle cover and thought I'd see how it looks on the car. I knew there was going to be some modifications needed so wanted to check it out.

Looks like on each end, the cover will need to be extended down to tuck under the DNA wings, see yellow arrows below

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026ScuttleCover1_zps771c78e2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026ScuttleCover1_zps771c78e2.jpg.html)

Also with the bonnet closed, the cover also fouls here (yellow arrows below) so this needs trimming back a bit as well

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026ScuttleCover2_zps6080c8a1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026ScuttleCover2_zps6080c8a1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026ScuttleCover3_zps1f592f4c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026ScuttleCover3_zps1f592f4c.jpg.html)

Finally below is the drivers side. I haven't tucked the cover underneath the wing yet, but the arrow points to wiper bolt  - it seems a very tight fit to fit the wiper arm back. I have lowered it, but may need to lower it further in order to clear the wing.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026ScuttleCover4_zps662a5cf9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026ScuttleCover4_zps662a5cf9.jpg.html)

Rudy/Beany, any chance you have a photo of your scuttle covers and what you did?

Thanks

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 27, 2013, 08:24:15 PM
My initial plan for this week was to get the car on 4 wheels in order for it sit on the ground and then reverse out onto the drive (which is more level ground) so I could sort out the bonnet alignment. Upon reflection, I don't think the ground issue would really make any difference, so the bonnet alignment never happened I'm afraid, but as you can see from my previous posts I was busy doing other bits. That said I just had to get the car out onto the drive to take so better photos of it, so here we are (sorry there is so many but was very excited  ;D )

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026CarFinal1_zps3861ef8e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026CarFinal1_zps3861ef8e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026CarFinal3_zps99b196f8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026CarFinal3_zps99b196f8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026CarFinal4_zps562dd68b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026CarFinal4_zps562dd68b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026CarFinal5_zps032ffc68.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026CarFinal5_zps032ffc68.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026CarFinal6_zps86ea55ea.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026CarFinal6_zps86ea55ea.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026CarFinal7_zps4522d7f8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026CarFinal7_zps4522d7f8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026CarFinal9_zps8f138c04.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026CarFinal9_zps8f138c04.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026CarFinal10_zps9d074bc4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026CarFinal10_zps9d074bc4.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026CarFinal12_zps0a6182d6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026CarFinal12_zps0a6182d6.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131026CarFinal13_zps25373b2d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131026CarFinal13_zps25373b2d.jpg.html)


Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 27, 2013, 08:31:42 PM
Finally... as promised here is the video that dad took when I got the car out of the car port. Click on the below image to view it

(http://i1315.photobucket.com/albums/t597/pjlucas1/th_20131026DNA430After176Hours_zps10382809.jpg) (http://i1315.photobucket.com/albums/t597/pjlucas1/20131026DNA430After176Hours_zps10382809.mp4)

Title: Re: Paul's 4thirty Build Diary
Post by: Darren on October 27, 2013, 09:19:18 PM
Another 430 sees the light of day
Well done, great progress
D
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on October 27, 2013, 10:05:39 PM
Watch the vid folks .... excellent work!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 28, 2013, 06:23:17 PM
Cheers for the comment Guys, and Steve for the one on the actual video on Photo bucket (although I had to look up who Huey Lewis was I'm afraid)  ::)
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on October 28, 2013, 07:57:19 PM
Huey rocks dude :)
Title: Re: Paul's 4thirty Build Diary
Post by: Bishlee on October 28, 2013, 08:47:23 PM
Wow! These kits do look good, don't they!!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 29, 2013, 01:47:30 PM
Guys, I've run out of BetaSeal - doesn't anyone know where I can get some more? Need it to stick the rear deck on...
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on October 29, 2013, 05:52:50 PM
Paul,
Car builders solution do one.
Used it myself and it's good stuff.
Rudy
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on October 29, 2013, 09:18:09 PM
I've bought TigerSeal from my local auto shop, excellent stuff.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on October 29, 2013, 10:24:22 PM
Cheers guys. Just bought some tiger seal off the bay. The only thing that annoys me a bit about CBS is their postage costs seem very high. Puts me off a bit. Need to save up and do a big order in one go.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on October 30, 2013, 12:03:03 AM
I agree with that. But that is exactly what I do.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 02, 2013, 06:06:45 PM
Total Build Time: 183 hours

Good six hours today. Nothing particularly showy but all important none the less.

Secondary rear deck release cables

Next I fitted the secondary rear deck release handles and cables

Like Phil, I decided to use the DNA pulls as the secondary ones. If you look in the rear bumper bar, near the middle is 2 holes about the size of a 10 pence. These are perfect for the pull T handles. The handles sit nicely in there and all they need is to be fed through the bumper bar and then up through the body work to the catches. My Anderson plug was in the way but I packed it out towards the rear of the car so it doesn't get in the way now. The T handles can just be tek screwed to the bumper bar once done. This is all a lot easier without the rear diffuser on.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102SecondaryCatches6_zps56c5544d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102SecondaryCatches6_zps56c5544d.jpg.html)


(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102SecondaryCatches7_zps38b8e00c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102SecondaryCatches7_zps38b8e00c.jpg.html)

With the DNA cables you need to do the following:

A) cut the rubber grommet off
B) cut the steel ball off the end
C) trim off some of the insulation

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102SecondaryCatches1_zps2f46e7b1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102SecondaryCatches1_zps2f46e7b1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102SecondaryCatches2_zps1d1271d3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102SecondaryCatches2_zps1d1271d3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102SecondaryCatches3_zps9a0470ab.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102SecondaryCatches3_zps9a0470ab.jpg.html)

To secure the cables I planned to use some electrical connection block (cheers Beany).

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102SecondaryCatches4_zps575afaef.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102SecondaryCatches4_zps575afaef.jpg.html)

I trimmed off some of the insulation from some electrical connection block (15 amp) and you have a good secure clamp. Will use 2 on each side for added strength.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102SecondaryCatches5_zpsb20cc99a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102SecondaryCatches5_zpsb20cc99a.jpg.html)

I added the brake adjuster to the body work after drilling a second hole for the secondary wires. I thought it be best to have 2 separate holes for each wire on each side. Will get 2 more adjusters for next week.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102SecondaryCatches12a_zpsbd42e3d2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102SecondaryCatches12a_zpsbd42e3d2.jpg.html)

I threaded the wire through and then made an eye with the wire and secured with the con block clamps. Works well.

Here are the secondary handles in place next to the Anderson clamp. The T bar handles are at a slight angle and this is how they naturally sat with the wire inside the bumper bar. Didn't want to have too many forced angles with the cables.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102SecondaryCatches13_zps3f5ca456.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102SecondaryCatches13_zps3f5ca456.jpg.html)

Repeated for the drivers side and fed wire though for the secondary cable but didn't wire up.

After that I had a look at the drivers side and where I could mount a new lever for the passenger side primary cable. I had originally planned to use the original MR2 boot release here but the cable would not reach without putting under carpet. I didn't fancy doing that nor extending the cable and as I need to get one more handle and cable set up anyway I thought I'd use the MR2 original cable for the primary drivers side.

So I fed the original back through the car and connected as the primary drivers side release cable.

Again you need to cut the wire ball off the end and then the insulation. Take care the insulation is tough. It has black plastic and then metal wires and then inside that is white plastic and THEN you have the pull wire itself! I found it best to grind through each layer with the bench grinder. Once done I wired it up through the brake adjuster as used con block clamp again. This wire is thicker so used a 30 amp con block. Two blocks as before.

All the layers cut back

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102SecondaryCatches10_zps17b116fe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102SecondaryCatches10_zps17b116fe.jpg.html)

Tape on for a neater finish

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102SecondaryCatches11_zps1cd7ce9e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102SecondaryCatches11_zps1cd7ce9e.jpg.html)

Connected up and working from the MR2 release lever on the car floor

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102SecondaryCatches12_zpsf5c0cad3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102SecondaryCatches12_zpsf5c0cad3.jpg.html)

So now I have the passenger secondary and the drivers primary release cables wired up. I didn't bother wiring up the secondary drivers side as no point until I get the brake adjusters. I have also ordered some brake cable ends to put on for a neater finish.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 02, 2013, 08:04:58 PM
Last week I spent time adjusting the pods to be more in line with the rear deck. However doing this adjustment I was wary that the pods would now not clip back as before as the gold catches were now not low enough.

I tidied up the excess fibre glass on the pods where they attach to the spring hinge as this fouls the gold catches (as there is an overhang) and then set about packing out the gold catches further.

Instead of more nuts to pack it out, I had these hard chunky cylinder blocks in the box. Don't remember where they came from but they were perfect. Slightly longer than the 3 nuts I was using and I had 4 left. Bonus! (I used these on the Anderson clamp as well to pack it out)

Fitted the gold catches again and now the pods fold right back and catch just lovely. Repeated on other side

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102GoldCatch1_zps9576a96b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102GoldCatch1_zps9576a96b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102GoldCatch2_zpsd3c9304f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102GoldCatch2_zpsd3c9304f.jpg.html)
 
So as I planned to bond the rear deck on next week I then etched and primed both the rear frame and deck so it would be dry in time.

Also cut out the rear brace bar finally. One of those things that always got pushed to the end of the to do list. Used a dremmel for this.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102RearBraceBar_zps70cd7525.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102RearBraceBar_zps70cd7525.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 02, 2013, 08:13:50 PM
Bonnet Alignment

Next I moved round to the bonnet and scuttle cover. I lowered the drivers wiper drive so the scuttle would slide underneath and took some measurements/photos of what needed extending (the sides) and what needs trimming away (the centre part). Will post details on this separately when I do it all.

So onto bonnet alignment. What a pain this is but got there in the end.

A couple of hints for future builders:

1) Don't bother having the bonnet catch fitted when trying to align the bonnet. It just gets in the way and can be added and adjusted once you have aligned and tighten up the bonnet.

2) The lower bolts attaching the hinge to the bonnet could mean it sits slightly too low right at the bottom. I added washers between bonnet and hinge to raise it slightly. See picture below

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102BonnetAlignment2_zpsf5784c91.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102BonnetAlignment2_zpsf5784c91.jpg.html)

3) Don't use a washer under the bolt head at the lower fixing point on the hinge to the wing. If you do it means the bolt can catch on the other parts of the hinge when it closes up and thus prevents it closing properly. The head protrudes too much. See picture below

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102BonnetAlignment3_zps9b6aa007.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102BonnetAlignment3_zps9b6aa007.jpg.html)

So with these hurdles out of the way I got it all tightened up and sitting as best as a could. Sorry, can't believe I didn't take a picture of this!!!  ::)

Added 2 bonnet stops on the wings. These were supplied by DNA and are the same as used on the rear frame. Trim the lip off as before so it fits in a circle hole

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102BonnetAlignment1_zps2da7c1fa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102BonnetAlignment1_zps2da7c1fa.jpg.html)

And also started drilling out the holes in the scuttle to attach more bonnet stops. These are the original MR2 ones. Will have to make the holes in the scuttle cover bigger also.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102BonnetAlignment4_zps29bf2136.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102BonnetAlignment4_zps29bf2136.jpg.html)

So got there in the end. Started then to align the bonnet catch but run out of time. Will add the bonnet stop to the scuttle at a later date.

Plan on thurs night is to bond on the rear deck once my tiger seal turns up! Might do some work on the scuttle cover during the week

Hope these hints help someone in future!

Always good to end on a full frontal... Put the roof up today. Really like the look of the car with the roof up. This is just as well I suppose as we lve in England!!!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131102FinalView_zpsd0eca390.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131102FinalView_zpsd0eca390.jpg.html)

Until next time...


Title: Re: Paul's 4thirty Build Diary
Post by: crossy on November 02, 2013, 08:21:32 PM
Looking good Paul! Seems to be moving along nicely lately, you must be well pleased  :D
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on November 02, 2013, 08:52:56 PM
Looking great buddy as crossy says coming together really well :)

Before you know it you will be ready for prep and paint.

I guess red ? :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 02, 2013, 09:20:41 PM
Thanks guys. Yes getting there.

Crossy - basically got a regular schedule going now. While I don't wanna rush things I don't want it dragging on more than a year really - At least getting it on the road that is. I know I'll be like Beany always fiddling with it but I want to at least get it on the road and back to my house within a year. So I'm working Thursday evenings and Saturday mornings. I start early on Saturdays (before 6am today) so I get to spend nearly 10 hours a week on it. Really enjoying it

Beems - yep. Red has always been my favourite colour so naturally it needs to be red. MADMAN will be pleased. 
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on November 03, 2013, 07:52:22 AM
Alright, who started this rumour that I'm "always fiddling with it"? >:(

Lol!!!!!!

Great progress report Paul, not sure why you have had to pack the folding pod catch so much though as mine fitted spot on, other than sanding I tiny amount from the inside of the pod, where the catch slides in. I guess all cars are slightly different.

I hope you manage your deadline, no doubt your sister will love arriving at her wedding in such a great car.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on November 03, 2013, 09:06:51 AM
Alright, who started this rumour that I'm "always fiddling with it"? >:(

http://www.youtube.com/watch?v=jUn0n9Yu7Vw (http://www.youtube.com/watch?v=jUn0n9Yu7Vw)
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on November 03, 2013, 09:45:19 AM
OOOOOKKAAAAAYYYYYY!!!!!!!!!!

Lol.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on November 03, 2013, 10:02:12 AM
sorry dude .... your comments just reminded me of dear old Dicky Emery
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on November 03, 2013, 10:30:51 AM
Unfortunately I'm old enough to remember him.

Wouldn't get away with half of his stuff these days. ::)

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Litho on November 03, 2013, 06:40:40 PM
Unfortunately I'm old enough to remember him.

Wouldn't get away with half of his stuff these days. ::)

Beany ;D

Another thing that's wrong with the world now!
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on November 03, 2013, 08:05:55 PM
Experience shows you rarely need the roof.  I went all the way down to Exeter in the rain and found that if you don't use the wipers the wind takes the rain up the screen and over the top.  If you use the wipers your right shoulder gets wet.
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on November 03, 2013, 10:48:04 PM
Until you stop in traffic :)
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on November 04, 2013, 09:52:02 AM
I carry a brolly, a Furrari one, unfortunately it's red.  Fortunately the only time I've had to use it is at shows.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 04, 2013, 10:14:33 PM
Just a quick one tonight guys. Started work on wing mirrors

Firstly I did some sanding work on the mirrors. Tried to get the worst of the flash lines off.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130411Wing1_zpse7474e83.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130411Wing1_zpse7474e83.jpg.html)

Next set about mounting the original MR2 mirror motor. These fit straight into the pressed moulding in the mirror. For the wire and plug I made a bigger hole (see below) so I could put through the wire connector as well as the wire itself. This doesn't really matter as it will all be hidden behind the glass, plus as my mirror are going to be removable I wanted this option. I also made a slight recess so the wire doesn't get trapped behind the motor once it is mounted (red arrow)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130411Wing2_zps476d8f01.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130411Wing2_zps476d8f01.jpg.html)

Then mounted the motor. I found it best just to put the motor in the pressed mould,  sitting nicely,  drill 1 hole and the tek screw in and the drill another, screw as so on...

So here we are.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130411Wing3_zps149539f0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130411Wing3_zps149539f0.jpg.html)

As for the wires, my concern is that where they are mounted on the car now, will they still reach the original MR2 mounting points or will they be too short? Can anyone remember?

But what I might do is, as my mirrors are going to be removable, I might make it so the where the mirrors unbolt from the car, i connect the wires up there to the main car loom (via a new connection plug). So basically I'll have a triangle shaped cover on the back of the mirror mount, remove this to expose the bolts to undo the actual mirror and disconnect the wire right there behind the triangle. Watch this space.  ;D

Title: Re: Paul's 4thirty Build Diary
Post by: seriph on November 04, 2013, 10:58:49 PM
Why do they need to be removable?

Do the mirrors on the genuine fold in and if so, do they do so electrically?

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 04, 2013, 11:13:51 PM
We'll I only have a single garage. And it is connected to my house. We often go and in and out of the house via the garage. With 2 girls in and out and the wife bringing stuff in thru garage I thought it would safer to at least have the drivers side mirror removable. While the mirrors aren't that much wider that the rear of the car they obviously stick out. They are just the right height to get banged with shopping bags, bums, kids heads etc... The car will be under a cover in the garage as well to protect the paint. On,y time will tell whether I can be arsed to remove it every time but I will try and make it as painless as possible.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 08, 2013, 09:13:29 PM
Evening all

Small update for you from Thursday night.

Worked on front bonnet and rear deck:

First I put the scuttle cover back on the car after cutting away the centre part, trimming away some excess plastic from sides (to make fitting easier) and started to extend the other bits that go into the top of the wings.

Below is the cover in place. Yellow circle showing the cut away middle part. Yellow arrow showing the extended parts. The cut away is a bit of trial and error but on the horizontal part I plan to add a rubber U channel strip to tidy it up at the end. Might fill the hole left with a mesh of some sort.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131108Bonnet2_zps3a9a39f1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131108Bonnet2_zps3a9a39f1.jpg.html)

Close up of extended parts. I will fill these in so they merge into the original cover parts eventually.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131108Bonnet1_zpsdce4911d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131108Bonnet1_zpsdce4911d.jpg.html)

Now what I found with the whole bonnet alignment is this: Previously I got it all nice with the scuttle bonnet stops in place and the catch aligned. But when it came to the scuttle cover (after removing the stops) and then fitting the cover, the bonnet and catch were out of line again.

I found the scuttle cover raises the bonnet up slightly even if it clears the raised centre part you've cut back. Where the bonnet shuts it rests on the lower part of the scuttle cover. You could cut away the part but there are fixing points there so I didn't want to.

So tip for future builders. Don't bother will bonnet alignment until you have the scuttle cover on. It won't take 5 mins to just trim back the centre bit to make it clear the bonnet but could save you hours of time. The cover can be tarted up and extended at a later time. So had to re adjust the catch. I then found that my bonnet stops were now too big/high. So they are not fitted at moment. Will see if I can fit some smaller ones elsewhere.  But at the moment it seems it doesn't need them really.

Here is the bonnet shut with the scuttle cover in place

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131108Bonnet3_zpsec716c56.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131108Bonnet3_zpsec716c56.jpg.html)


******************

The main task of the night was rear deck bonding. So me and the rear deck went to the pub! Haha!  ;D Anyway, (that is why I don't have a job in comedy....) I decided to go ahead without Dad as I had done my homework and planned exactly how I was going to do it.

The key thing here is preparation. Have everything to hand such as weights, gloves, rags etc..and do a dry run of the process so you know exactly where you're going to put weights etc. Double check it all aligns up ok before you begin. Warm the adhesive an hour prior to make application less tiresome. I made weights out of old bricks, paving stones wrapped in newspaper. I also used tool boxes as they spread weight over a wider surface area.

I bonded mine with the roof up. That way you can ensure the is no interference with the roof frame etc.

Here are a few pictures.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131108RearDeckBond1_zps219607df.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131108RearDeckBond1_zps219607df.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131108RearDeckBond2_zps54b6df4b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131108RearDeckBond2_zps54b6df4b.jpg.html)

Fingers crossed it has dried ok. I have bonded the whole deck apart from the thinner side bits that reach to the windows. These can be done afterwards once the main area has dried. I read up on it and it seems easier to do in 2 stages.

Tomorrow if needed I can inject more black stuff in any gaps between frame and deck from the inside. But hopefully that is the last of the messy stressful jobs.

So that's it for now.
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on November 08, 2013, 09:45:49 PM
Looking good Paul its nearly there now with bonding :)

Paint shop soon then ? :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 08, 2013, 10:59:23 PM
In theory,  yes Beems, but in reality no.  :(  I am planning to build as much as the car as possible before sending it to paint.  I would rather get all the things like wiring, interior bits trimmed and trail fitted, scuttle covers, arch liners etc.. done before the cars goes away then have to worry about them when it comes back painted. As you know there is a lot of trail and error fitting on these builds and I'd rather have to do it without worrying about scratching the fresh paint work. Also I know what I am like, as soon as it is painted i'll want to get it out on the road.  ;D so I'd want the time between that to be as short as possible. It's swings and roundabouts really. I know there are some jobs like air intakes that can only really be done after painting but i am trying to keep those to a minimum. Possibly February 2014. That will be a nice valentines gifts for my wife!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 09, 2013, 08:07:53 PM
Total Build Time: 194 Hours

After bonding on the rear deck Thursday night, this morning was the moment of truth. I am happy to report the deck managed to stick to the frame and I am pretty pleased with the results.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109FirstBond1_zps259d164d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109FirstBond1_zps259d164d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109FirstBond2_zpscd92efec.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109FirstBond2_zpscd92efec.jpg.html)

There is still a lot of gaps between the deck and the frame at various points but these can be filled in with sealant later.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109FirstBond3_zpsc3f725a1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109FirstBond3_zpsc3f725a1.jpg.html)

Also, as predicted by Phil, the aggressive gas-rams are a thing of the past now. When the catches are released the deck pops ups about 20 cm and then slowly rises. Will rise even slower once the heavy glass is in and the dummy engine is also attached.

Next as it was still early I needed to do something quiet so I search for the rear number plate lights and fitted them. I had to remove my number plate holder first.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109NumberPlateLights1_zps300d6897.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109NumberPlateLights1_zps300d6897.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109NumberPlateLights2_zps04e6bd8a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109NumberPlateLights2_zps04e6bd8a.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 09, 2013, 08:56:14 PM
Next I worked on the rear deck releases. First I trimmed the drivers main wire and added a cable end to keeps things tidy

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109Catch1_zpsa9362b49.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109Catch1_zpsa9362b49.jpg.html)

Then wired up the drivers secondary cable after adding a brake adjuster to the body work

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109Catch2_zpse80e229f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109Catch2_zpse80e229f.jpg.html)

So I still needed to fit 1 more pull and cable - the passenger main one. To recap, I had used the DNA ones as secondary pulls and installed on the bumper bar behind the rear number plate. I had used the factory MR2 boot release for the driver’s side main release and I wanted to install a lever type pull and cable for the passenger main release - installed behind the driver’s seat so I could open the rear deck from the driver’s side of the car. . I had looked on eBay for boot release cables and found one off a Fiat Punto for £8 second hand. Lever, cable and catch! Sorted! I didn't need the catch obviously!

Here is the Punto Lever et al…

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131108PuntoRelease_zps6ad7a30c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131108PuntoRelease_zps6ad7a30c.jpg.html)

Below is where I planned to install the lever. I pulled back the carpet and there is a thin metal panel which is sort of double skinned but the gap between the two skins is about 2 cm so there is room to get your fingers in to add nuts to bolt the lever to. I used the large circle hole to get access to put one nut on and the other side can be done as then metal opens out. The small hole already there is what a trim plug fits into through the carpet to keep carpet back.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109Catch3_zpscbcfaa0b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109Catch3_zpscbcfaa0b.jpg.html)

Holes drilled for the lever

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109Catch4_zpsecd83ff7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109Catch4_zpsecd83ff7.jpg.html)

Carpet put back and holes cut for bolts, plus a slit for the cable once installed

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109Catch5_zps4314d424.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109Catch5_zps4314d424.jpg.html)

Then I added the lever via nuts and bolts. It was quite awkward but got there in the end. Just remember to attach the cable to the catch AFTER you’ve fed it through the carpet, otherwise you’ll feel a bit of a Wally if you realise after you’ve gone through the pain of bolting the lever to the body work! Here it is in place.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109Catch6_zpscc47e41d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109Catch6_zpscc47e41d.jpg.html)

I just fed it along behind the carpet and up through the same hole where the fuel flap release cable went and attached it to the catch like before. Simples!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109Catch7_zps45f7f0b0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109Catch7_zps45f7f0b0.jpg.html)



Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 09, 2013, 09:22:13 PM
Next I looked at my scuttle cover and marked exactly where I needed to fill out the extended part, to. Will remove from the car and fill it out and then trail fit it to get it just right

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109Scuttle1_zps3baeb8a5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109Scuttle1_zps3baeb8a5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109Scuttle2_zpsee058d1c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109Scuttle2_zpsee058d1c.jpg.html)

Next up was the trimming back of the under bonnet cover. OH MY LORD! What a job this is! All I can say is do this BEFORE the car is painted. It is really is a massive trial and error exercise. I started on the passenger side and then did the top and then the driver’s side. TIP -  take the cover off the fuse box as it will make fitting easier and also remove the alarm trigger as this also gets in the way of fitting. I recommend doing this on something like a garden table as a B&D workmate it too small and it will drive you insane. The B&Q power file was worth its weight in gold for this job!

This is what the cover looks like before any trimming

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109BonnetCover1_zps344ad58d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109BonnetCover1_zps344ad58d.jpg.html)

And after

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109BonnetCover2_zps69d31829.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109BonnetCover2_zps69d31829.jpg.html)

The yellow arrow is where I have cut out so I can access the cap for my washer bottle that is installed on the outside of the frunk. The red arrow is where you should just completely cut in 2 to make fitting easier round the back of the fuse box. You can’t see the cut as it is under the wing.

The only bit of over trimming I did was here just in front of the fuse box, but it something I can live with. If the metal below is black you’ll hardly notice

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109BonnetCover3_zpsdc99018a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109BonnetCover3_zpsdc99018a.jpg.html)

So here we have it all done and fitted

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109BonnetCover5_zps44899413.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109BonnetCover5_zps44899413.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109BonnetCover6_zps3b9d084f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109BonnetCover6_zps3b9d084f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109BonnetCover7_zps75cbd762.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109BonnetCover7_zps75cbd762.jpg.html)

There is a rubber trim that goes on the bottom of the scuttle cover that I guess would bridge the gap between this and under bonnet cover. That can be fitted at the end later.
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on November 09, 2013, 09:50:32 PM
Such an awesome diary mate. Great work too. That cable pull is a sweet looking item - adds a real factory look. Forgive my ignorance but are two cables required to pop the back cover? If so, is it possible to fit them onto the one lever or even electrify them?

... Or am I misunderstanding the whole drivers side- passenger side lever thing?

Also, if you sprayed behind the abs insert black your over-trim would be almost invisible. Just a thought.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 09, 2013, 10:02:07 PM
Morning Steve, no you haven't got it wrong. I've got 2 sets of cables - primary and secondary, should something go wrong with the primaries. I have 4 levers/pull handles. Yes you could connect up 2 cables to one lever. People have done this in the past and it works fine. It's swings and roundabouts really. TBH the levers are so close to each other it doesn't really matter. Yes having just one to release both catches would be better but you still need to fold the front seat forward to sort the roof out so I figure why worry about trying to get both working off the one lever. It would probably take longer to do than installing 2 seperate ones and as in my situation, I'd still need to buy a cable from somewhere, so £8 all in is a small price to pay  ;D

Yep, once the cover is off I will give it all a paint of satin black and you wont see it. Behind the bonnet catch you can see red aswell so I'd plan to hide this as well.. Lovely jubbly!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 09, 2013, 10:08:36 PM
As I had bonded the rear deck on, I thought it about time I took over the dummy engine and see what the fit was like. It seemed fine although I sense that the Ferrari logos on the red parts are higher than the sides of the rear deck. I will have a look at my glass tomorrow to see if it is concaved enough to clear it. I know I have seriously modified my dummy engine, but the amount it sticks out from underneath is no lower than the original dummy engine. It is just mesh instead of plastic. It rests on the strut braces on the original MR2. I hope I don’t have to cut anything away from it as that would be a real shame and from every other photo I see, no one else has had to do this.

Here are the photos. Shame it wasn’t in daylight as I wanted to see how it looked with the mesh at the bottom looking thru into the real engine area.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109RearEngine1_zpsd755c411.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109RearEngine1_zpsd755c411.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109RearEngine2_zpsb92da2c9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109RearEngine2_zpsb92da2c9.jpg.html)

Here is the exhaust silencer cover I knocked up. It is not perfectly symmetrical yet, but I will work on that and get it bolted in place. Then I can add the hinges for the dummy engine. I have gone bigger than the DNA supplied hinges – 10cm long as my engine is much heavier now with all the metal and bits added so thought I’d get some bigger ones. I did plan to bond them to the engine as there wouldn’t be much room for bolts, but upon reflection I’ll used countersunk bolts and just have nuts showing from the top side. You won’t be able to see them when the deck is shut

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109RearEngine3_zps647e2f98.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109RearEngine3_zps647e2f98.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109RearEngine4_zps37745a1a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109RearEngine4_zps37745a1a.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 09, 2013, 10:29:46 PM
So the final thing for the day was the bonding of the front parts of the rear deck. Let’s call these the deck flaps for the sake of this post.  I left these to the end as this is a bit of an art-form as I didn’t want to have a gap left between these and the body work below.

So again, I did a trail run of exactly how I was going to do it. Initially I thought I was going to need clamps etc. but my home-made weights came up trumps again.  I removed the pods for this exercise as a) they weren’t lined up and b) they just get in the way. Some of my weights are standard bricks covered in newspaper. These are perfect to slide under the edges of the roll-bar carrier cover and to force down the deck flaps. I then added another weight on top to be sure.

So now was time to get the black stuff out again. I had already used 1.5 tubes of tigerseal on the deck, so used the rest of the tube and some other Stikaflex I had. I went about filling in gaps between the rear deck and the frame with the Stikaflex and the rest of the Tigerseal. Then it was time to apply it to the frame inside to secure the deck flaps. You may recall I had added to the DNA frame previously using shelving unit metal. Below is a picture showing the bond in place one the added part and a drawing of the shape of the part I added

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109FinalBond4_zpse0655e4f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109FinalBond4_zpse0655e4f.jpg.html)

I really rammed this full of sealant and weighted it all down. Other side:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109FinalBond5_zps00e7a5e5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109FinalBond5_zps00e7a5e5.jpg.html)

I’ll see how it goes next week, but I may pack it out further back and add more sealant

So this is the state of play with the rear deck. The red arrow showing the brick wedged in pushing down.  The yellow arrow showing the deck flap weighted down with the gap below minimized.


(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109FinalBond1_zpsa408f9e3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109FinalBond1_zpsa408f9e3.jpg.html)
 
(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109FinalBond2_zps01319617.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109FinalBond2_zps01319617.jpg.html)

The heavy toolboxes on again to press down on the freshly applied sealant on the back of the rear deck.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109FinalBond3_zps09cf6ee6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109FinalBond3_zps09cf6ee6.jpg.html)

Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on November 09, 2013, 10:45:01 PM
Not sure the glass is concaved enough.i had the same with mine and the dummy engine pushed the glass up out of recess so had to re adjust the height of deck etc.if the deck runs too low in the quarters it could need bringing up to allow a few mil of clearance.also buddy the chequer plate does your rubber adjuster on deck frame hit it when deck closes as when buffer wound full in can cause rear if deck to rise up.i had to trim out that area to allow buffer to touch the body and not the plate.yours may be fine buddy just checking lol :)

Great detail mate its a superb build diary
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 09, 2013, 11:06:33 PM
Thanks Beems - will have to cross that bridge when I come to it. The rubber adjusters at the back. Well,  to be honest I had forgotten all about them! When I fitted the chequered plate the rear deck looked no different to how it was before really. So hopefully they are having no effect from that perspective. The rear deck at the back seemed fine. I added more sealant in some gaps on the passenger side but I was happy with how it was lying. Not a lot I can do about it now. Will have to wait till next week. Seems the dummy engine doesn't sit down flush against the MR2 body work 'step' (where the brace bar was removed). Maybe work there can be done and thus clear the glass.
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on November 10, 2013, 01:50:46 PM
Great update Paul, you're really cracking on with it

I was wandering if the issue with the engine clearance was because you have lowered the rear deck so much in the front.

My prancing horse pretty much touches the underside of the engine glass and that's with the rear deck at it's regular height. Hopefully you'll be able to trim some of the underside to get the dummy engine sitting lower.

Best of luck with it.

Beany  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: tenpin on November 10, 2013, 01:59:14 PM
If there's still a problem with the engine touching the glass, you could always sand down the lettering and logo a bit - it won't notice. That was one of the things I had to do when seeing if it was possible to fit one of those engines to my 3Sixty.

 - tenpin
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 10, 2013, 02:24:32 PM
Cheers Guys for all your help. I've had a look at the glass this morning and it does have a slight curve in it, so that's a plus. Beany, the engine photos were taken before I bonded on the front parts of the rear deck! Maybe it will make it worse or it might cause the middle bit to pop up slightly higher, but will have to see. What the main issue is I think is the dummy engine itself. The mesh that I stuck under neath add's depth as it is difficult to created a right angle bend in it without it bowing out so I may have to do away with that. That's a shame but not the end of the world. The metal bars that I added I made sure were no lower than the original DNA mould so hopefully they will not need to be trimmed. 
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on November 11, 2013, 04:33:46 PM
Is the moulded engine a hollow shell or supported in some way underneath?

Also, how flexible is it? Maybe some steel could be bonded to the underside to make it very slightly concave?

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 11, 2013, 09:07:33 PM
it is hinged at the back and the hinges attach to the plate you put across the hole in the rear body work that gives you access to the exhaust silencer. the box part of the engine rest on the diagonal strut braces that attach to back of the rear brace and the front bit of the engine is actually just flat and it goes over the area where the roof folds into. will post a picture up when i get the chance
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 11, 2013, 09:24:52 PM
Checked on the rear deck this morning. All dried and I'm pretty pleased with how it has all turned out. Here are some pictures.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131111RearDeck1_zps91ef58e7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131111RearDeck1_zps91ef58e7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131111RearDeck2_zps8d70349f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131111RearDeck2_zps8d70349f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131111RearDeck3_zps367035be.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131111RearDeck3_zps367035be.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131111RearDeck4_zps5c960847.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131111RearDeck4_zps5c960847.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131111RearDeck5_zpsf9645a32.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131111RearDeck5_zpsf9645a32.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131111RearDeck6_zps18debb4d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131111RearDeck6_zps18debb4d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131111RearDeck7_zps17821aef.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131111RearDeck7_zps17821aef.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131111RearDeck8_zps3e074885.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131111RearDeck8_zps3e074885.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131111RearDeck9_zps4db40d00.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131111RearDeck9_zps4db40d00.jpg.html)

I also checked out the bonnet adjuster that Beems had pointed out. Yes, you can see that in the photo below it was touching the silver chequered plate I had installed. However it didn't seem to be effecting the height of the rear deck really. There is a but if flex in the chequered plate as I hadn't bolted it down yet.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131111Stop1_zps2ec77ea3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131111Stop1_zps2ec77ea3.jpg.html)

I removed the plate and had a look at actually where these adjusters hit the bodywork. Mine actually half hit the raise lip of the exhaust silencer access hole. I checked the frame by giving it a good shake and there is no rattling/vibration.  I looked at the adjusters and I have a good 10mm left to screw them in should I need to, so I think I'm gonna be okay, but thanks for the tip Beems. It could have so easily gone the other way!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131111Stop2_zpsa17d4857.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131111Stop2_zpsa17d4857.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on November 11, 2013, 09:33:03 PM
Hi Paul

No problems buddy thought if it was pushing deck up could save you some problems.

Cars looking good buddy coming together nicely now.

Always best to fit deck with roof up saves major problems lata.

I can see it now all shaped up and in glossy red.will look great mate

Keep up the good work mate :)
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on November 11, 2013, 10:03:29 PM
Red? RED!!??

Why not anthracite with navy interior

;)

But seriously: your photos and build diary is brilliant mate. You're trying a bunch of stuff that illustrates why quality building is the only way to fly.

Again, well done.

It's also great that other members help so willingly and share real insights into making some aspects of the build far more manageable.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 13, 2013, 10:03:58 PM
Couple photo updates

As the dummy engine was out, I thought I'd fit the hinges at the back so that job was out the way. I used bigger hinges than the ones DNA supplied because I've added a lot of weight to my dummy engine with mesh and metal so thought bigger hinges would be better. I used 1cm allen bolts as the wont pro-trude much from under neath and this area is bolted nearly flat to the exhaust silencer cover

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131113Engine1_zps211582c1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131113Engine1_zps211582c1.jpg.html)

I also nicked Beem's idea of fitting a rubber grommet to the engine  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131113Engine2_zpsbddb70d6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131113Engine2_zpsbddb70d6.jpg.html)

Filled in the scuttle cover extension parts - will trail fit the cover tomorrow night to see what the initial fit is like

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131113Scuttle1_zpscb4d5af5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131113Scuttle1_zpscb4d5af5.jpg.html)

Also I've fitted a rubber trim to the bit that is cut back to allow the bonnet to close for a better finish. Need to check whether with the trim on, more plastic needs cutting back! It isn't brilliantly clear in the photos - see arrow

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131113Scuttle2_zps80978a4d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131113Scuttle2_zps80978a4d.jpg.html)

Steve asked how the dummy engine fits to the car, so I have atempted to explain with the below pictures

Here is a side profile of the engine. You can see on the right, it is actually flat. This parts fits over the roof storage area of the car. Moving to the middle of the dummy engine you can see the little step shape where the dummy fits with the contours of the original car. Moving further back the dummy actually sits over the real engine and clears it as it rests on the strut braces (blue line) of the car. And then on the left the hinges I added are attached to a make-shift cover than cover's the exhaust silencer access holes in the body work.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131113Engine3_zpsaa283a4b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131113Engine3_zpsaa283a4b.jpg.html)

The reason why my engine doesn't fit right yet, is because of the mesh I have added underneath (green arrow above). This means the dummy extends lower and thus when it rests on the strut braces, the top of the dummy is higher, and would hit the glass. I will probably remove the mesh and see how it clears.

Below shows the step (yellow arrow) and the strut braces (blue arrow)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131109RearEngine4-Copy_zps9e5dd469.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131109RearEngine4-Copy_zps9e5dd469.jpg.html)

Hope this helps





Title: Re: Paul's 4thirty Build Diary
Post by: cheets on November 13, 2013, 10:17:29 PM
Paul Looking good can you not drop the  strut braces lower at the front were it fits ?
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 13, 2013, 10:34:54 PM
Didn't think that would be possible or advisable as it could cause structural issues. Anyone else done this? For the sake of some mesh I'm not sure it is worth the worry.  :-\
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on November 13, 2013, 11:16:40 PM
I removed my brace and I know other people who has too.you can make 2 steel plates to drop brace but I never had any flex problems.
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on November 13, 2013, 11:40:59 PM
I made two plates and lowered mine
MADMAN
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 14, 2013, 07:34:26 AM
Ah I see, so you did away with your brace altogether Beems.

MADMAN how thick was the steel that you used? There aren't any picture anyway are there? Will have a loook at the car tonight when I go over

Cheers all
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 15, 2013, 09:00:28 PM
Quick update from last night

First I cut away the rubber trim that rests on rear brace bar. This could get in the way of the dummy engine.

Before

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114RearBrace1_zps8a6ac7d4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114RearBrace1_zps8a6ac7d4.jpg.html)

After

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114RearBrace2_zps70709003.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114RearBrace2_zps70709003.jpg.html)

Next added some rubber pieces to go at the bottom of the catches to remove any movement

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114Catch1_zps6983e0ad.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114Catch1_zps6983e0ad.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114Catch2_zps2bbf1576.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114Catch2_zps2bbf1576.jpg.html)

Modified my gloves next: Yes it is starting to get a bit chilly now, so gloves are a must and to avoid the grazed knuckles! But I always find myself taking them off to do the more fiddly work. Solution – cut the end off! Genius!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114Glove_zpseaf7fe0b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114Glove_zpseaf7fe0b.jpg.html)


Next, I worked on fitting back the rear pods and getting them aligned. I know there is a lot of detail on here and on other builds about what bolts to what etc... So I won't repeat but I would definitely NOT use Nyloc nuts here. As the nuts are a bit awkward to get to once the deck is bonded on you want to be able to do them up reasonably tight by hand, so you can still move them into position and they stay put enough for you to then tighten with a spanner. Nyloc nuts would not allow you to do this.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114Pod2_zpsd50f7725.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114Pod2_zpsd50f7725.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114Pod3_zpsfb0ccac6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114Pod3_zpsfb0ccac6.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114Pod4_zpsada0ba3d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114Pod4_zpsada0ba3d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114Pod1_zpsd04a4e77.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114Pod1_zpsd04a4e77.jpg.html)

My whole philosophy with the rear deck was this:  Trail fit everything before bonding so you understand how it all fits together and get it lined up reasonably well but be prepared for things moving around slightly once the deck is stuck.

The rear deck is the driving part of the equation. The position of this drives everything else.  It has to be flush at the rear and sides and then the front near windows. Next then is flappy pods. These have to follow the humped bits of the rear deck and the sides. Last is the roll bar cover. It is this part I feel that is the balancing item/the plug that is made to fit the rest.

Here are some photos of how mine went. Driver’s side is a better fit but I may look to fill in the gap in a bit so it is more uniform (arrow)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114Pod6_zps145036c9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114Pod6_zps145036c9.jpg.html)

On the passenger side it was a different story. Firstly the pod is different shape on the face that faces front of car. There is more GRP that needs to be ground away to at least create a gap (Red arrow). Next is roll bar cover itself as it is too high at this point (yellow arrow).

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114Pod5_zps3b8fafdd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114Pod5_zps3b8fafdd.jpg.html)

I found some ways to help adjust the roll bar cover to get it sitting better:

If you want it lower at the front and it won't go, it may be fouling on the below part. (Yellow circle) This is inside the rear glove box area. I pushed it back slightly by hand to allow the cover to go further in. This metal plate has a screw hole in it so it could be used to secure the cover here eventually.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114RollBarCover3_zps559dcf09.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114RollBarCover3_zps559dcf09.jpg.html)

Also another area where it can restrict it is this part here. The GRP (yellow arrow) can bang on this (red arrow) and prevent the roll bar pulling down lower

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114RollBarCover1_zps25d507cc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114RollBarCover1_zps25d507cc.jpg.html)

I ground away part of the GRP which allowed the cover to sit lower. I had to re drill my bolt hole but that was no issue really. I cut ground back to where the red line is.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114RollBarCover2_zps84b71da2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114RollBarCover2_zps84b71da2.jpg.html)


The result is the cover sits lower now and it flush with the pod and looks pretty good against the rear deck as well.

Also I had removed the rear lip part of the cover (like Phil did - see his build) to enable it to sit lower at the back of it should it need to.

I had drilled holes at the back of the cover to screw it to the vertical part of the mounting bracket but don't think they are needed. I have since filled them in with P40

I don't have any photos as next I filled in the unwanted holes with P40. Will post later after Sunday

I had to pack out my gold catches (YET AGAIN) but now on passenger side they work a treat. However on driver’s side it still doesn’t work due to:
a)   the position of the pod and how it was attached to the hinge,  
b)   where the gold catch locates
So when you try to lock it, the catch hits the nut that secures the pod to the hinge! See photo below – the direction of the arrow.  I am happy with the pod location so I think the easiest thing to do I re-drill the hole in pod and hinge and re-bolt so the catch clears. Would rather that then have to drill through the frame and move catch location holes.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114GoldCatch_zps9e78b5a4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114GoldCatch_zps9e78b5a4.jpg.html)

So as the P40 was drying I could do no more on the rear deck stuff, so I moved to the front. I had brought over the scuttle cover so I thought I’d see how that measured up. Adding the cover seemed ok, despite the extended sides and I am pretty happy with the results. I may rub down the extended parts just a little more so they are lower, but I don’t think I can get it better than this. Pictures below:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114Scuttle1_zps52f19aad.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114Scuttle1_zps52f19aad.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114Scuttle2_zps763a626c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114Scuttle2_zps763a626c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114Scuttle3_zps11795799.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114Scuttle3_zps11795799.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114Scuttle4_zps1ef6eb25.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114Scuttle4_zps1ef6eb25.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114Scuttle5_zps367c2639.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114Scuttle5_zps367c2639.jpg.html)

So with the roll bar cover off I had a look at the actual roll bars and how they would fit. They seem to be handed. Which is the correct way? I think Photo A looks the better way but if anyone could let me know for definite I’d really appreciate it:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114RollBar1_zps1ccaec4f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114RollBar1_zps1ccaec4f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131114RollBar2_zps0efe1051.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131114RollBar2_zps0efe1051.jpg.html)

Cheers
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on November 15, 2013, 10:08:52 PM
excellent write up yet again mate!!

I think roll bars in the A position are correct as B doesn't look right!!

I am trying to get the roll bar surround lined up with the rear deck first and THEN sort my pods out as they have the most adjustment available...
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on November 15, 2013, 11:31:27 PM
Ah I see, so you did away with your brace altogether Beems.

MADMAN how thick was the steel that you used? There aren't any picture anyway are there? Will have a loook at the car tonight when I go over

Cheers all
Aprox 4mm thick from memory,
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 15, 2013, 11:38:59 PM
Thanks matey. I may still try without lowering them. As a first instance at least.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 17, 2013, 09:06:49 PM
Total Build Time: 205 hours

Good six hours today.

Fitted 3rd brake light into rear deck using the brackets I had made a month earlier

(http://i1315.photobucket.com/albums/t597/pjlucas1/201311173rdBrakeLight_zps232e1825.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201311173rdBrakeLight_zps232e1825.jpg.html)


Rubbed down the holes I had filled in on the roll bar cover and set about fitting it

The actual roll bar takes M8 bolts at the middle part. I tried the bolts first to cut the thread in the bar better thus saving time for later when actually fitting them. I definitely do this first as they can be a bit fiddly to get the bolt started in the thread


(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117RollBar1_zps6742dbda.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117RollBar1_zps6742dbda.jpg.html)

Here is the view of the pre-fit up of the bars

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117RollBar2_zpsfc3e49b3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117RollBar2_zpsfc3e49b3.jpg.html)


(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117RollBar3_zpse8f077c4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117RollBar3_zpse8f077c4.jpg.html)


When I had the roll bar cover on, I noticed 2 issues.

1) the pre drilled holes in the bracket were not in the right position so I set about enlarging them

From this…

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117RollBar4_zps14c42731.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117RollBar4_zps14c42731.jpg.html)


To this.


(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117RollBar7_zpsb8f2c1f7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117RollBar7_zpsb8f2c1f7.jpg.html)

as with everything you need to allow for adjustment!  ;D


2) there is no way to bolt the bars up without drilling access holes in the underside of the cover


(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117RollBar5_zps67f74618.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117RollBar5_zps67f74618.jpg.html)


(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117RollBar6_zps798e6e6d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117RollBar6_zps798e6e6d.jpg.html)


These are pre-marked. I also drilled a hole in middle to access the handle to release the roof when it is folded away (more on this later).

You can see the pre-marks (yellow arrows above) but for the middle I didn’t think it was necessary to cut it all away. A circle would do.

While I was here I wanted to re-fit the storage bins to see how it was all going to fit together. I previously had a concern about how the petrol flap wire was going to lie under the bins, but all was fine. The shell of the driver’s side storage bin has a hollow and the wire was placed under this hollow (see arrow).

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117FuelLatchCable3_zps21c8a834.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117FuelLatchCable3_zps21c8a834.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117FuelLatchCable1_zps28494228.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117FuelLatchCable1_zps28494228.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117FuelLatchCable2_zpsb304ad5f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117FuelLatchCable2_zpsb304ad5f.jpg.html)

Bins and doors refitted

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117StorageBins1_zpsc76e0d77.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117StorageBins1_zpsc76e0d77.jpg.html)


(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117StorageBins2_zps2273d924.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117StorageBins2_zps2273d924.jpg.html)

Roll cover and bars now fitted. I used large repair washers on the middle holes to cover the enlarged gaps made in the bracket earlier

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117RollBar8_zpsa7193a9a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117RollBar8_zpsa7193a9a.jpg.html)

The bolts on the outer holes, you need to drill through the Perspex blocks and then use longer M8 bolts and washers. I would advise to place the head of the bolt underneath and have the nut on the top as there is no way you’d be able to fit the nuts and washer underneath if you did it the other way around. Definitely no access for hands there!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117RollBar9_zps896c4fa3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117RollBar9_zps896c4fa3.jpg.html)

Another job done - finally fixed my gold catch issue on the driver’s side. Re-drilled the hinge bolt hole and moved. Catch still wasn't perfect. Guess why? It was now packed out TOO LOW! Oh how I laughed. Removed some packing and now works a treat. AT LAST!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117GoldCatch1_zpsf700e9cf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117GoldCatch1_zpsf700e9cf.jpg.html)

Next I filled in the gaps that were left between the rear clip and the original body work (that were exposed once I cut away the rear brace bar part), with Stikaflex. I also added more Stikaflex to gaps between the rear deck and the frame. Then I added the rubber trim that came from the scuttle cover to see how it would look. This finishes it off and bridges the gap between the scuttle cover and the under bonnet covers.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117Scuttle1_zps37c58444.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117Scuttle1_zps37c58444.jpg.html)

The roof when folded flat locks into a catch mechanism to keep it secure. With the roll bar cover on it is not possible to access the catch without some modifications.

Here is the catch as I had left it. I couldn’t remember whether I had taken anything off this or not – so long ago. It has 2 screws holes that can take some bolts.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117RoofHandle1_zps89f4b9e4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117RoofHandle1_zps89f4b9e4.jpg.html)

Here you can see the bolts I trail fitted

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117RoofHandle2_zps38f18e9e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117RoofHandle2_zps38f18e9e.jpg.html)

I thought I’d pack it out further and then add some sort of lip just so I could get to it to release it from under the roll bar cover. Packed it out with the usual black spacers and washers and for the lip bit I had these square shaped washers. They fitted perfectly side-by-side.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117RoofHandle3_zps8b996f13.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117RoofHandle3_zps8b996f13.jpg.html)

Fitted

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117RoofHandle4_zps5732eb29.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117RoofHandle4_zps5732eb29.jpg.html)

Works a treat with the cover installed.

So here is the end result of the roll bar cover et al. Doors closed

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117RollBar11_zpsed83e7f5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117RollBar11_zpsed83e7f5.jpg.html)

The only gripe I had is the top of driver’s side door catches on the bottom of the cover (see arrow). I have filed away the edge part but it doesn’t really help. It is not that bad, but the door catches ever-so-slightly on the cover thus it could potentially rub paint off. Not that you are really going to see it. Plus if I raise the cover up enough, it puts the rear deck out of alignment.


(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117RollBar10_zps5b933413.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117RollBar10_zps5b933413.jpg.html)

What I think I’ll do is maybe pack out the edges of the cover that hit the door with foam/rubber trim once painted so it purposely doesn’t shut flush under the cover and adjust the latches so they still catch. We’ll see. Just one of those things. Hopefully it will help others though in the future! 

Finally, I started looking at the Z flaps. Using the DNA hinges, I attached on via 1 tek screw and screwed it in tight enough so the hinge would hold in position but still be adjustable. I think it is best to bond the flaps to the hinges as they are so thin, you couldn’t screw them really. I curved the hinge to stop it catching the pod above.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117ZFlaps1_zps7853d5be.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117ZFlaps1_zps7853d5be.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117ZFlaps2_zps14a98a3c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117ZFlaps2_zps14a98a3c.jpg.html)

Then bonded and stuck it to set in the right position

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131117ZFlaps3_zpsa1518a45.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131117ZFlaps3_zpsa1518a45.jpg.html)

Once it is bonded, I can then drill and fit the other screw in the hinge. Will do the other Z flap Thursday night hopefully
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on November 17, 2013, 09:58:12 PM
Hi Paul good work buddy

I would do the z flap mod like madman and Rudy and Beany.far better finish and less prone to damage
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 17, 2013, 10:23:34 PM
Hi Beems. What mod is that? Is it with extra piece of rubber added to the flap or something to hold it back when folded back?
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on November 18, 2013, 12:27:55 AM
No buddy send madman a mail he will explain how it works.far better than the standard way
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 19, 2013, 06:25:11 PM
So as per Beem's advice, I contacted MADMAN who kindly sent me some photos of the z flap modification. As I under stand it, if you installed the flaps how I have done in when the roof it up they need to fold outwards into the cabin of the car (if that makes sense) They have to do this because if they fold backwards I guess they'd get in the way of the roof mechanism. As they fold into the cabin, they is a risk they get banged and potentially broken by people's shoulders. As I can be a big, lumbering wally I cetainly don't want this. So I have started to build this modification.

Went to B&Q today and got some normal kitchen cupboard hinges. I have also made this extension bracket out of some of the left-over metal L-shaped strip I used for the dummy engine.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131119ZFlapHinge1_zps8e946ad9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131119ZFlapHinge1_zps8e946ad9.jpg.html)

Bolted together

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131119ZFlapHinge2_zpsc2dd6611.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131119ZFlapHinge2_zpsc2dd6611.jpg.html)

This is how it will work. The hinge is bolted into the roll-bar carrier bracket at the yellow arrows. Then the actual z-flap is attached to the bracket part I have made. This way when you fold it back, it locks back under the rear deck further back, hopefully out of the way of the roof. The z flap is locked in a parallel position to car length-wise. Manta did a similar modification but using a different type of hinge. I'll need to cut away part of the roll bar carrier like Manta did, but I'll detail it all here..I just need to un-bond my z flaps from the hinges that I did on Sunday. Hopefully I can manage it!  Fingers crossed.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131119ZFlapHinge3_zps9b140996.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131119ZFlapHinge3_zps9b140996.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 23, 2013, 10:59:40 PM
Total Build Time: 212 Hours

Evening everyone. Worked on the car Thursday night and Saturday morning. Most of the time was spent on the z flaps. Here is the detail on these:

Z Flaps

Even though these flaps are very small they require a lot of work. The following is for those who have never have done them and for those that have, they know what I mean!  ;D
The problem with these flaps is this: IF you fit them with just butt hinges you’ll encounter problems. Things are very tight around this area when the roof is up (which let’s face it, in the UK it will be most of the time). Using the butt hinges means that the z flaps will have to fold forwards into the car. This means that they get in the way and there is a risk that you hit them when you get in and out of the car (with the roof up)

Last week I attached one of them using the butt hinge and this is what they looked like. With the roof down and them in situ, they look fine:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap1_zpsc3a3893b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap1_zpsc3a3893b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap4_zps9117ee2d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap4_zps9117ee2d.jpg.html)

However, if you fold them back they look like this. They don't clear the roof:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap2_zps64c41a15.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap2_zps64c41a15.jpg.html)

And folded forward they look like this. Here you can see that part of the roof hit them. Mine didn’t even fold forward enough.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap3_zpsc297a2e3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap3_zpsc297a2e3.jpg.html)

So the set-up needs to be changed (DNA, please don’t think I’m complaining, it is just ones of those things  ;D)

The above shots were taken Thursday night and I had already started on the modifications with the new cabinet hinges. The thing is, the L-shaped brackets I had made were not suitable. They were not long enough and the z flap would just not work. So Thursday night was a bit unproductive but I did learn a lot, so hopefully for others it will be less hassle. If you search the forum for z-flaps you’ll find loads of pictures of what others have done to over-come this.

First of all you need to start by cutting out parts of the roll bar cover. You need to get rid of the raised part to allow the new hinge to work. Here is the roll bar cover before:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap6_zps39b54b54.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap6_zps39b54b54.jpg.html)

And after:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap7_zpse4c748b4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap7_zpse4c748b4.jpg.html)

A lot is cut away….

Next I had to re-do my L-shaped bracket that attaches to the hinge. Now, previously I had used 1 piece of metal, but you’ll see that in order to get the z-flap mounted, it is best done on a slope as the roll bar cover is sloped on the vertical plan. Therefore, I used 2 separate pieces of metal using some cut down right-angled brackets. This way they can be independently adjusted/twisted etc accordingly.

L-Shaped bracket Mark 2:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap8_zpsd0cefa5d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap8_zpsd0cefa5d.jpg.html)

Mounted: It helps to mount the hinge facing slightly upwards to help with the angle of the z-flap when fitted.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap9_zps558c7298.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap9_zps558c7298.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap10_zpsa15dd52b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap10_zpsa15dd52b.jpg.html)

After Thursday night I re-thought how I’d attach the attach z flaps. I didn’t want to bond them. I’d rather bolt them so they could be adjusted afterwards. So after I was happy on the line up, I drilled holes from the inside and then countersunk the holes from the outside to take some counter-sunk screw bolts. Once finally done, these will be filled (like the door handles) to hide the screw heads. The lower part needed packing out, but this was no big-deal with washers.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap11_zps34bb61ae.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap11_zps34bb61ae.jpg.html)

Bolted:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap12_zpsf8f98343.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap12_zpsf8f98343.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap13_zps674817aa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap13_zps674817aa.jpg.html)

Folded back. Now the z flaps folds right back inside the car and out of the way of the roof mechanism

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap14_zpsb1335ad7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap14_zpsb1335ad7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap16_zpsf0ffc113.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap16_zpsf0ffc113.jpg.html)

Folded back out – I mounted them with plenty of adjustment available for later. But the hard work is done

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap18_zps3538acfe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap18_zps3538acfe.jpg.html)

Driver’s side:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap19_zps8fc9ff9a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap19_zps8fc9ff9a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap20_zps445696f0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap20_zps445696f0.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131123ZFlap22_zpse2935a49.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131123ZFlap22_zpse2935a49.jpg.html)

I’d say this job took a good 6 hours from start to finish. But hopefully for others with this help it will be half that time.
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on November 24, 2013, 12:59:23 AM
Silly question: would it be simpler, neater and easier to have these components fully removable? I mean, that one could pop them off and place them on the rear floor when not in use? Probably seems a dumb idea but I'm thinking about the possibility of them requiring endless adjustment if bumper etc.

Apart from that - well done on providing an excellent (as always) build diary mate
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on November 24, 2013, 09:55:29 AM
Silly question: would it be simpler, neater and easier to have these components fully removable? I mean, that one could pop them off and place them on the rear floor when not in use? Probably seems a dumb idea but I'm thinking about the possibility of them requiring endless adjustment if bumper etc.

Apart from that - well done on providing an excellent (as always) build diary mate
            I think it has been done using industrial magnets to locate and remove them, then comes the chance of loosing them
MADMAN
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on November 27, 2013, 05:54:02 PM
Worked on wing mirrors last night. Can someone tell me whether the mirror should touch the window glass? I've got the removeable plates on mine and their thickness makes the mirror base move further from the window. I plan to make a Beany chopping board plate to cover the inside of mirror but the distance I need to make up to glass is 2cm. Surely if the mirror hits window it is going to interfere with the window going up and down? Does it matter. If I can narrow the gap a bit I think it would be ok. The door weather strips running the full length of the door either side of window glass should address the water leaking issue. What have others done? Thanks guys.
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on November 27, 2013, 06:14:05 PM
Sent you pm
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on November 27, 2013, 06:49:36 PM
They don't touch the glass buddy but I'm sure Rudy can evaluate how it all fits together and what touches what.its fine using the plates buddy :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 01, 2013, 08:24:38 PM
Total Build Time: 221 Hours

Good 7 hours on car today. Here are a few updates for you all as it’s been a while since I posted any photos.

First I worked on the wiper blades. I have extended the scuttle and had fitted it back to see how it looked. Please with it so far, but I wanted to make sure that the wipers were all fine, especially the driver’s side as you need to lower the wiper drive (as per the DNA video) as it tucks under the wing. I wanted to make sure the actual wiper arm cleared it.

Lowering the drive is relatively simple, just unbolt it and replace with longer bolts and pack it out with larger nuts. I put a small amount of super glue on the packer nuts to hold them in place as it is very awkward to do the bolts up so didn’t want these moving about as well.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201Wipers1_zpsb144df77.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201Wipers1_zpsb144df77.jpg.html)

Thought it would be worth mentioning that when you undo the wiper drive and it falls down, don’t do what I did and reverse the direction of it by changing the side the rod connector thing goes. Ensure that it is at the bottom pointing towards the front of the car. In the picture below the arrow points to the front of the car. If you put it back differently, then the spindles will turn in different directions and so will your wipers. Doh!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201Wipers2_zps745f1dc6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201Wipers2_zps745f1dc6.jpg.html)

Just place in one bolt and then test the wipers and check both spindles move in the same direction before doing it up fully.

Here is the drive down up, again arrow points to front of car

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201Wipers3_zps084fbaf6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201Wipers3_zps084fbaf6.jpg.html)

With the arms back on this is the clearance you have on the driver’s side

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201Wipers5_zps6ca70068.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201Wipers5_zps6ca70068.jpg.html)

So now wiper arms and blades are back on and working fine. A tip when bolting the arms back on: have the wipers going on a slow intermittent wipe, and then when it stops, turn the ignition off. You now know that the wipers are at the off position on the spindles so you can fit them in that position.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201Wipers4_zps03541889.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201Wipers4_zps03541889.jpg.html)

I will change the actual blades as I have some that have tubes/jets on them as you need this as the DNA bonnet doesn’t have the jets like the MR2 does, but this is for a later date. Maybe Dad can do that when he’s back on his feet.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 01, 2013, 09:03:01 PM
Next worked on the door card fitting:

Started by fishing out the MR2 door rubbers and fitting these back first as wanted to see what the situation was. Here is the rear part on the passenger door

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201DoorCards1a_zps577eb930.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201DoorCards1a_zps577eb930.jpg.html)

Here is the view at the front. You’ll need to cut away the rubber above the yellow line as this is not needed and pokes through the door gap when shut if you leave it. Leave it till the end once you’ve done the door card.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201DoorCards2a_zps685f894e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201DoorCards2a_zps685f894e.jpg.html)

Here is the driver’s side. On the rear part, I have now removed the rubber to the left of the line as the door car fits over this. The rubber goes over a metal plate that fixes to the door. I have kept this in place so the rubber set up can still attach to the car using its original mountings.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201DoorCards1_zps26d7d376.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201DoorCards1_zps26d7d376.jpg.html)

Here the in the front rubber again you need to trim above the line.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201DoorCards2_zpsf5727a8f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201DoorCards2_zpsf5727a8f.jpg.html)

So the actual fitting of the door car is a lot of trial an error. Luckily Dad had done a lot of the grunt work in the summer with these so I didn’t need to do much. You will have already folded down the metal parts of the doors before you’ve even bonded on your kit ages ago, but I also had to grind down metal as well so that the door card top was level with the external door skin. (See one of my previous posts ages ago where I talk about this). You’ll never get it perfect, but I am pretty happy with it.

One little tip is to cut off a bit of the bolt that is circled below. I don’t know what attached to it, possibly the door pull on the original MR2, but it protrudes too far and hits the bottom of the door car and thus prevents it sitting flush onto the MR2 door.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201DoorCards3_zps866de9be.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201DoorCards3_zps866de9be.jpg.html)


I just added a couple of washers and a nut and then did it up tight. Then trimmed it back.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201DoorCards4_zpsacaa3d77.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201DoorCards4_zpsacaa3d77.jpg.html)

Here is the rubber trimmed away from the door rubber I was just talking about. If you don’t cut away the metal it can still attach in the original way using the little black popper (arrowed).

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201DoorCards5_zps6a7a3253.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201DoorCards5_zps6a7a3253.jpg.html)

Here is the front rubber trimmed and fitted. Arrow showing the trimmed part

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201DoorCards6_zps218aadc8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201DoorCards6_zps218aadc8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201DoorCards7_zps704ba650.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201DoorCards7_zps704ba650.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201DoorCards8_zpsc1c25bec.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201DoorCards8_zpsc1c25bec.jpg.html)

So once happy just drill holes through the door card and door and screw in place. I did 2 holes at the back, 2 at front and 3 or 4 along the bottom.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201DoorCards10_zps9ea7f1c7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201DoorCards10_zps9ea7f1c7.jpg.html)

Here is it with the door shut

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201DoorCards9_zps8602fcdb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201DoorCards9_zps8602fcdb.jpg.html)

Here the window is up showing how it hugs the rubber at the back of the window

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201DoorCards12_zps55c7a25c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201DoorCards12_zps55c7a25c.jpg.html)

And the front

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201DoorCards13_zps0e119ed1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201DoorCards13_zps0e119ed1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201DoorCards14_zps303740cf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201DoorCards14_zps303740cf.jpg.html)

I started to fit up the passenger side but run out of time. I kept breaking thin drill bits as well. Nightmare!  You’ll need to trim off other bits of the door card – yellow lines below, when you first get them, but that’s part of the fun!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201DoorCards11_zps43478d0a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201DoorCards11_zps43478d0a.jpg.html)

When the door cards are being fitted finally I will use some other ‘nicer’ looking screws but for now black tek screws will do.

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 01, 2013, 09:29:58 PM
Finally, I had to do something ‘pretty’ today so I fitted back in the rear lights. Back in the early days when the rear clip was in the garage waiting to be fitted, Dad spent a good while cutting out the holes for the lights etc.. and getting them all looking nice. I had only ever seen photos of them, never in the flesh, and I must say he’s done a really good job on them all, so here are the pictures.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201RearLights2_zps8b70d75c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201RearLights2_zps8b70d75c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201RearLights1_zps45368d40.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201RearLights1_zps45368d40.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201RearLights3_zps2514f0cd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201RearLights3_zps2514f0cd.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201RearLights4_zps17278d4c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201RearLights4_zps17278d4c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131201RearLights5_zps2b49519e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131201RearLights5_zps2b49519e.jpg.html)


I don’t want to leave these on for too long due to risk of damage whilst doing the rest of the car, so will look to get the wiring done on these after I’ve finished the initial fit of the passenger door card, so I can then remove them and tuck them safely away again!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Darren on December 01, 2013, 09:36:40 PM
keep up the good work, soon be ready for pre paint :)
D
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on December 01, 2013, 09:54:29 PM
Great work Paul car looks really lovely.as d says won't be too long now.you deserve all the credit its great build (also ur dad) keep the pics coming :)
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on December 01, 2013, 10:13:50 PM
Paul, it's looking great mate. Credit to you and keep the great work going. I was at your stage this time last year. Looking at your build just brings so many memories. Good on you mate. Enjoy.
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on December 01, 2013, 10:43:52 PM
Congrats mate. Wish I was there to lend a hand but doubt you need it!

Can we expect to see any carbon in the interior?

Finally .... Hope dad's well - pass on the regards of all fellow dna fans from the colonies.
Title: Re: Paul's 4thirty Build Diary
Post by: sundog on December 01, 2013, 11:07:59 PM
Paul what's the first thing your going to do in your new f430!!!? :)
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on December 02, 2013, 10:24:28 PM
She's a credit to you Paul going to be great when she's in paint well done top job
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 03, 2013, 11:48:49 AM
Thanks for comments everyone. They are a big help.

Sunny - first thing i'll do is prob take my poor-suffering wife out for a spin. Maybe even treat her to a trip to Tesco's LOL  ;D

Seriph - maybe some carbon in the interior, but then plan is to just get the seats/door cards/roll hoops trimmed first and get the car on the road. I plan to do the interior properly later, maybe winter 2014/15 and look to build a centre console like Cheets is doing, and change the dashbaord layout etc.. But i want to get the car on the road first and back to my house and enjoy in the slightly 'better weather' we have in summer at the moment.

Sent Dad your regards - he is on the way up now thankfully.

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 03, 2013, 11:52:46 AM
At the weekend I also clamped on my wing mirrors and with Dad's help measured them from tip-to-tip. This is the widest part of the car. So for all people in future who search the forum to find out the actual width of the car (as I know it's a popular question - I certainly looked for the answer) here it is:

The DNA 4thirty / 430 kit car width/dimensions is just under 81 inches wide (approx 2m 5cm) . This is from wing mirror to wing mirror. I'm sure this will help someone in the future.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 03, 2013, 11:54:47 AM
tried searching and it works a treat!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 04, 2013, 08:40:44 PM
Started working on the rear light wiring. This is a job you can happily do away from the car, in the warm, on the sofa in front of the telly with a beer to hand. Don't try and do it in a cold garage with numb fingers as there is really no need!

Here is a step by step guide to what I did:

Used Tenpin's wiring guide in his 360 build diary at the below link.
http://www.dnaoc.co.uk/index.php/topic,91.msg6486.html#msg6486

Copied the text and pasted into word and printed off 3 copies of it. Used 2 copies to cut out as labels for all the various wires.

Here are the Superseal connectors than came with the kit. There are 4 in total and 4 wire connectors on each.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131204Wiring1_zps3602eae6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131204Wiring1_zps3602eae6.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131204Wiring2_zps7b5d6da5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131204Wiring2_zps7b5d6da5.jpg.html)


The yellow caps come off and the silver pins slide into the holes and click in place. The blue plugs slide onto the wire and then insulate the whole thing.

I bought loads of wire off eBay. It was suitable for car wiring and I got 50m worth for under £15. You get 10 x 5m lengths and you can choose from a range of colours so you can try and match up with the original MR2 wire colours. Not that it really matters. I didn't get all the same colours but got most.

I started by cutting the wire I'd need. I went for 1m 20 cm lengths as I didn't want to take any chances as I couldn't refer to the car as it is at Dads. I'm sure it is plenty. Better to have too long wires than too short.

Next push the blue plug onto the wire. There is a hole in the blue plug even if you can't see. Push on the end you’re going to attach to the connector to and ensure you have it the right way round. (You could fit the blue plug right at end but then you'd have to slide the plug along the full length of the wire as you need to start it at the other end! Bit of a time waster)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131204Wiring3_zps9c5bedf6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131204Wiring3_zps9c5bedf6.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131204Wiring4_zpsbca9fa37.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131204Wiring4_zpsbca9fa37.jpg.html)

Next I stripped the insulation off one end of each. Probably about 1.5 to 2cm off. Twisted the copper strands.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131204Wiring5_zps6dbecf9c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131204Wiring5_zps6dbecf9c.jpg.html)


Place the wire into the metal connector. Ensure the longer prongs at the end when bent down with pliers touch the insulation not the copper wire so they grip well. Ensure you push the wire right into the connector and also squeeze together the smaller prongs so it catches the copper wire strands.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131204Wiring6_zpsbe7b369f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131204Wiring6_zpsbe7b369f.jpg.html)

Then the connector slides into the correct slot like below. You’ll hear a small click when it is in. Then push the blue plug into the main housing to seal around the edges

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131204Wiring7_zpsb01e4c8a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131204Wiring7_zpsb01e4c8a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131204Wiring8_zps894096a1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131204Wiring8_zps894096a1.jpg.html)

Repeat for all the wires and then add the correct wires into the correct holes accordingly and you build up the main light plug connector.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131204Wiring9_zps475b6dcb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131204Wiring9_zps475b6dcb.jpg.html)

Next when all done label up the wires accordingly from the cut out of Tenpin guide.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131204Wiring10_zpsa0c77dad.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131204Wiring10_zpsa0c77dad.jpg.html)

I included everything on the label.  The hole number, the function of the wire and the colours that tenpin note’s in the guide, so this way when you are at the car and joining it all up, you’ll know exactly what to join to what. This is especially important if you don’t use the same coloured wires like me.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131204Wiring11_zps91f8f067.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131204Wiring11_zps91f8f067.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131204Wiring12_zps000b34d9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131204Wiring12_zps000b34d9.jpg.html)

Next I needed to insulate the wires. So I used something called Amalgamation tape. It comes on a roll that has a lining. When you unroll it and peel off the lining, it is basically very thin rubber than when it is wrapped around something it sticks to itself and forms a nice insulated, waterproof seal. It can also be stretched as well. Plus if it isn’t quite right, you can undo it and re position it and it still sticks back very well.

I needed to have the wires taught so clamped them between 2 chairs and then started wrapping the tape around tightly, overlapping each time slightly.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131204Wiring13_zps3a6b15cc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131204Wiring13_zps3a6b15cc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131204Wiring14_zpsfac94f9c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131204Wiring14_zpsfac94f9c.jpg.html)

And then you are left with something like this

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131204Wiring15_zpsb05ed6fd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131204Wiring15_zpsb05ed6fd.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131204Wiring16_zpsac609b3f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131204Wiring16_zpsac609b3f.jpg.html)

Now they are all ready to fit up to the car at the weekend. Simples.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on December 04, 2013, 09:55:41 PM
Heh. Chair clamp. Bloody genius.

Well done in a great wiring thread mate.
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on December 05, 2013, 08:29:43 AM
paul, not bad, but you need to add a little more detail to your posts  ;D ;D ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 05, 2013, 09:02:05 AM
yep, i must try harder Phil.. sorry about that  :)  even more photos
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 05, 2013, 02:48:31 PM
Great write up Paul (as usual)!  :) Are you going to join these up the other end to plug into the existing MR2 set up or are you doing away with these and have something else in mind?
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 05, 2013, 03:56:56 PM
I just plan to wire the other ends to the MR2 wires. I guess I'll cut off the plug that is at the end of the MR2 part first, strip back the wires and then join the wires all up. Unless there is another way that people do it? I'll connect each individual wire seperately, wrap heat shrink round the join and when all done, wrap the amalgmation tape over it all so it is one seamless black wire...
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 05, 2013, 06:43:22 PM
Yes, Paul that would work as you are sealing everything well. I did mine the other way round, running my wires from the MR2 existing plugs then into the Ferrari light connectors. There wasn't a lot of spare wire to play with so I think you've done the right thing and it will allow you to route the wires better. I'm just not that good when it comes to wiring so preferred to just plug into the existing MR2 set-up!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 05, 2013, 07:22:52 PM
gotcha.. well in theory it should all be fine. i know the colours of the mr2 wires and i have labelled everything up so it should be just a case of matching it all up! of course things don't always go to plan.. so we'll see, but i'll put the results on here for all to see!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 06, 2013, 07:39:43 AM
Just don't buy any block connectors from B & Q or you'll start another debate!!!! LOL :D
Title: Re: Paul's 4thirty Build Diary
Post by: theblackknight on December 06, 2013, 10:26:48 AM
no need for the tenpin i the black knight has removed it! ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 07, 2013, 05:25:05 PM
Wired up the rear lights today. All working fine. I will post a full update with pictures tomorrow but for now here is a short video of the various lights working. Click on below image to play

(http://i1315.photobucket.com/albums/t597/pjlucas1/th_20131207DNA4ThirtyRearLights_zps51d26fec.jpg) (http://i1315.photobucket.com/albums/t597/pjlucas1/20131207DNA4ThirtyRearLights_zps51d26fec.mp4)

 
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 07, 2013, 06:55:25 PM
Nice work Paul! Aund very descriptive and helpful video  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on December 07, 2013, 08:43:55 PM
With the brake lights, I was gunna replace the bulbs in the inner half with dual filament so that the brake lights light up the full circle, but I think someone said that you cant do that, as the brake light has to be a certain distance from the fog light and it wouldnt be if you did this mod!!
Title: Re: Paul's 4thirty Build Diary
Post by: rsoles on December 07, 2013, 08:55:01 PM
100mm minimum distance between i think
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 08, 2013, 09:38:32 AM
Rear Light Wiring Part 1

Spent a good deal of time yesterday getting the rear lights wired up. Took over the Ferrari connectors I had built up during the week ready to be mated to the MR2 wiring loom.
I started on the passenger side. Here is the original MR2 rear light connector. Arrow points to the thicker of the 2 greens wires in the set up.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights1_zpsa448d942.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights1_zpsa448d942.jpg.html)

I just cut the white plug part off and then stripped back the insulation on the wires.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights2_zps3acbac55.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights2_zps3acbac55.jpg.html)

Then one-by-one I started to join the wires together. Don’t forget to slide the heat shrink on before you start joining the wires! I slid all heat shrink onto the extended Ferrari leads I had made first before I began.

To join the wires, bend each end into the little hook shape like this:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights3_zps0580cf0a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights3_zps0580cf0a.jpg.html)

Then hook together and twist

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights4_zps65b186a8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights4_zps65b186a8.jpg.html)

I added a bit of solder for strength. Don’t use too much or the heat-shrink won’t go on over the top. The hook and twist method makes it pretty secure.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights5_zps07f96aba.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights5_zps07f96aba.jpg.html)
Slide heat-shrink on

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights6_zpsd47791a4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights6_zpsd47791a4.jpg.html)

And heat it to fit

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights7_zps58e8a81e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights7_zps58e8a81e.jpg.html)

Done, not particularly pretty but it will all be covered in Amalgamation tape anyhow.

For the earth (common) connectors, you only have 1 wire on the MR2 part, but 2 earths on the Ferrari leads – one from each connector. So I basically mated both Ferrari earths together first, and then hooked these to the MR2 earth. Because of this, the whole area was thicker as there is more wire here, so I needed a larger heat-shrink

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights8_zpse8d27e3d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights8_zpse8d27e3d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights9_zps4cacf32f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights9_zps4cacf32f.jpg.html)

So after a while everything was joined up. Be prepared for a bit of back ache when doing this as you are leant over the rear side of the car for a while! Arrow is the original MR2 wiring.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights10_zps10aaa6ec.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights10_zps10aaa6ec.jpg.html)

Next I tested it all. Everything worked fine except the reverse lights. I thought maybe the car actually had to be running for these to work but as it was too early to start the car up I left it for now and then wired up the driver’s side next. In doing this I noticed the following things (notes for future builders)

1)   On my 2003 MR2 the passenger side wires were exactly as tenpin described in his guide, colour-wise.
2)   On the driver’s side however on my car, the indicator wire was NOT green/black, it was green/yellow. I have looked in the official wiring manual and this is the case. So take care. It was no big deal really as all the other wires agreed so it was just a process of elimination. But better to know before you start. 

I was thinking about the reverse light not working and trouble-shooting what it could be, possibly a fuse but then I thought as everything else worked, maybe it is the fact that the unused connector on the inner lamps is in fact reverse and vice versa.
So I swapped them over and bingo, the reverse lamp works perfectly. It is just one of those things. Tenpin’s guide is for a 360 wiring really not a 430 so it seems there is this slight difference with the wiring set up on the 430 lights. I’m sure tenpin won’t mind me saying this as I wouldn’t want future builders to spend ages trying to work out why the reverse lights didn’t work when in fact it was just this!  So to summarise:
For the 430 lights, use tenpin’s guide with the following notes:
1)   Reverse: put in plug hole # 2 not #3. #3 is not used
2)   Indicators: driver’s side wire is green/yellow

Below is the swapped over wires. For the unused hole, I still put a wire in (without a metal connector) to seal up the whole plug like Beany did.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights11_zpscd0d146a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights11_zpscd0d146a.jpg.html)

So now it was all working, I wrapped all the wires in Amalgamation tape to get it all sealed up. I left the labels on the wires as they won’t do any harm and if I ever need to take them apart and unravel the tape they’ll still be there.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights12_zpsd0cc93bd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights12_zpsd0cc93bd.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 08, 2013, 10:47:09 AM
Very detailed and helpful post as per usual Paul! Your build diary is going to be so helpful to anyone building a 430 and I'm sure will be greatly appreciated!  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 08, 2013, 12:48:10 PM
Rear Light Wiring Part 2

Next was laying the wires in the car and connecting them up to the lights. In hindsight I made my wires far too long, but I wanted to ensure a) I had enough and b) is could route them in the best way away from the exhaust. 75cm should be plenty. I did 120cm! I recommend doing this with the rear wheels off.

I fed the wire through and rested them on the holes where the rear lights go. I taped them there temporarily.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights13_zps947ae4df.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights13_zps947ae4df.jpg.html)

Then I attached a zip tie on a tree and stuck to the inside of the rear arch.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights14_zpsb6041484.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights14_zpsb6041484.jpg.html)

Then I arranged the wires accordingly inside the engine area. As my were so long I had to create a loop of wires and secure it down using zip ties and more trees. Managed to get it as neat as possible and think it looks fine. (Arrow points to the wiring I had done earlier for the Anderson charging plug)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights15_zps0f99c938.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights15_zps0f99c938.jpg.html)
 
The light wires fit nicely in this little gap on the rear clip (see arrow below)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights16_zps1d3cdf44.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights16_zps1d3cdf44.jpg.html)

Here is the view from inside the wheel arch. Arrow points to the wires for the temporary rear deck release pulls I fitted.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights17_zps4a695edd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights17_zps4a695edd.jpg.html)

Rear deck shut, wires don’t get in the way which is nice.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights18_zps683ca0e0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights18_zps683ca0e0.jpg.html)

Here is the zip tie on the other side. Do it up loosely when you first lay the wires and then when you have got it just right inside the engine compartment, then tighten it up.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights19_zpsf6843cee.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights19_zpsf6843cee.jpg.html)

Wires tidied up inside engine bay.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights20_zps903471c9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights20_zps903471c9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights21_zpsb3716a77.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights21_zpsb3716a77.jpg.html)

View from inside arch

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207RearLights22_zpsccbadc0a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207RearLights22_zpsccbadc0a.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 08, 2013, 01:33:43 PM
So just a few other things that I done yesterday: Looked into the rear number plates light wiring. The original connectors for these are attached to the rear bumper bar. These were unplugged and put away when the car was being stripped. As the rear clip is further back that the original MR2 rear bumper was these wires need to be extended. They are currently 20cm long. I think if they are extended to 50cm then this is ample. The original wires on the bumper bar as secured nicely, so thought there was no need to disturb them.

Below is the view of the leads clipped into the MR2 connector on the bumper bar. Red arrow show the connectors on the bumper bar

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207NumberplateLights1_zps2d9606ff.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207NumberplateLights1_zps2d9606ff.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207NumberplateLights2_zpsb76e3096.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207NumberplateLights2_zpsb76e3096.jpg.html)

I didn’t bother extending them yesterday as this is something I can do in the evenings during the week, away from the car.

Finished off fitting the passenger side door card:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207DoorCard1_zpse1e8ec98.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207DoorCard1_zpse1e8ec98.jpg.html)

Fitted the door seal back: This time I didn’t need to cut the edge as the door card was trimmed to allow the rubber to fit underneath. Upon reflection this is probably the better way to do it, so I think I’ll be in the market for another driver’s door seal if anyone has one? Second hand obviously

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131207DoorCard2_zps48ebbb3d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131207DoorCard2_zps48ebbb3d.jpg.html)

I wanted to then start fitting up the arm rests and door pockets but I realised I had left these bits at home! Doh!

Also starting looking at the piece of plastic that goes under the bonnet to bridge the gap between the MR2 and the front part of the car. No photos yet as still working on it.

Total Build Time: 229 Hours
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 08, 2013, 08:31:07 PM
One more small update. Bit of overkill really on the photos but extended the number plate wires. I added about 35cm of extra wire into them, and once done they are around 50cm long now. I also re-used the original outer covering in the middle, and covered the remaining wires with amalgamation tape.

Originals

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131208NumberPLateLights1_zpsf51c6678.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131208NumberPLateLights1_zpsf51c6678.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131208NumberPLateLights2_zps97496aaa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131208NumberPLateLights2_zps97496aaa.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131208NumberPLateLights3_zps8ea2b31a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131208NumberPLateLights3_zps8ea2b31a.jpg.html)

Extending Complete. Arrow points to the original covering

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131208NumberPLateLights4_zps4f44c832.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131208NumberPLateLights4_zps4f44c832.jpg.html)


Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on December 08, 2013, 09:14:18 PM
Man, I thought my build thread was detailed.

Excellent job Paul.  Still on schedule for the big day?

Are we all getting an invite for a bit of convoy action?  Lol.

Beany  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: tenpin on December 08, 2013, 10:10:37 PM
Re: wiring diagrams etc
I've attached the latest version, which I thought had been posted when I did my 5cudo - the 3Sixty lamps use different pins from the 4Thirty and 5cudo lamps as stated in that doc. However, what the doc doesn't mention is that my car was an '04 facelift model so the MR2 wiring may be different.  :(

 - tenpin
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 10, 2013, 09:34:55 PM
Cheers Tenpin, I never saw those diagrams. I just used what was in your 360 diary - on one of your posts. Anyway, I have worked it out eventually and now my diary has your diagrams posted so that is cool. Thanks.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 10, 2013, 09:39:00 PM
Man, I thought my build thread was detailed.

Excellent job Paul.  Still on schedule for the big day?

Are we all getting an invite for a bit of convoy action?  Lol.

Beany  ;D

Haha, imagine that! My sister would love that! I really don't know. It goes in waves, somedays I think the end is getting nearer and then other days i think, OMG I still have miles to go. We'll see. It will be ready when it's ready. I am at a stage now where I can build a part, and when I'm happy with it, take if off again ready to be fitted back after painting, which is nice. (the rear lights for example) This will make the reassembly much quicker and easier (hopefully)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 10, 2013, 09:59:31 PM
Bit of an update for you. Nothing new built really, just getting things ready for Thursday/Sunday.

Below is the 3rd brake light flasher unit I have bought. This fits between the wiring loom and the 3rd brake light.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201312103rdBrakeLightFlasher1_zpsb5aac119.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201312103rdBrakeLightFlasher1_zpsb5aac119.jpg.html)

Thinking about the mounting of this, (as it seems a bit of a vulnerable piece of equipment)  I am thinking about housing it in a box. Below is a small box purchased from Maplin today to house it. Should work well. Just a couple of holes drilled either end for the wires.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201312103rdBrakeLightFlasher2_zps6ee80ebb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201312103rdBrakeLightFlasher2_zps6ee80ebb.jpg.html)

Next keeping on the theme of cheap products from the high street. Next stop was Ryman the Stationers! WHAT??? I hear you ask? Basically for the exhaust hole cover I have got some chequered plate that I had to trim down each end. The cuts are not perfectly straight and the edges are very sharp so I thought about putting some trim on them. Rubber doesn’t really work as it is too flexible and the chequered parts make it sit up. So I thought out those black slide binder things you slide on A4 paper to hold a load of sheets together. The height of the chequered plate is 30cm as well (same as A4 paper) so used one of these on each end.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131210EdgingStrips1_zpsf38c191a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131210EdgingStrips1_zpsf38c191a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131210EdgingStrips2_zps2e4ce9f9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131210EdgingStrips2_zps2e4ce9f9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131210EdgingStrips3_zpsa5b765bc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131210EdgingStrips3_zpsa5b765bc.jpg.html)

I plan to paint the chequered plate all satin black at the end.

Here are the bits for the induction kit I plan to fit. These arrived today. This is the air feed that you need to fit an induction kit on the MR2. The MAF sensor sits in the hole.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131210InductionKit1_zps5a7e3457.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131210InductionKit1_zps5a7e3457.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131210InductionKit2_zps9270514c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131210InductionKit2_zps9270514c.jpg.html)

Here are the bits from the induction kit. I plan to fit it like Rudy has done in the wheel arch and have it connected to the pod by the petrol flap

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131210InductionKit3_zpsfae8d023.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131210InductionKit3_zpsfae8d023.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131210InductionKit4_zpsb89436a2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131210InductionKit4_zpsb89436a2.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: sundog on December 10, 2013, 10:01:28 PM
V nice paul ;)
Title: Re: Paul's 4thirty Build Diary
Post by: cheets on December 10, 2013, 11:29:06 PM
Nice Paul were did you get the induction kit from ?
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on December 11, 2013, 12:08:43 AM
Doing it like you mean it again! Love the innovative searching  -  it's amazing when we learn to "see," how many things can be repurposed into useful objects.

:)

This complete entrance was what I designed and built in 2009   -  After bushfires went through our region I wasn't sleeping well (at all really) so I decided to build this ... the only bit I had was the (unglazed) half-round fanlight frame at the top. EVERYTHING except the glass (stained and clear) was made from stuff I had laying around the backyard  -  the two "columns" I wanted to have made but I got a quote of $380AUD for them and simply didn't have the funds so I went on the hunt ... they are actually discarded PVC downpipe, coupled with ground-out wooden curtain rings to help them appear like turnings  -  it worked out really well I think and the rings enabled perfect fitment to the door's frame with 4 inch screws ... totally concealed when I fitted the rings over them.

there's no such thing as scrap  -  just stuff we haven't worked out what to do with yet. I love the innovations all the builders here demonstrate  -  it really is uplifting to know I am not the only wierdo around who sees useful objects everywhere! Well done again Paul


BTW the whole thing cost me $360 in materials ... door handle is fashioned from scrap copper water pipe - the fingerplates are scrap brass


Apologies for the semi-OT post.

:D



(http://i1098.photobucket.com/albums/g364/Steve_Ansell/AA%20Kilmore%20Renovation/Hallway6.jpg)
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 11, 2013, 07:41:41 AM
Bit of an update for you. Nothing new built really, just getting things ready for Thursday/Sunday.

Below is the 3rd brake light flasher unit I have bought. This fits between the wiring loom and the 3rd brake light.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201312103rdBrakeLightFlasher1_zpsb5aac119.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201312103rdBrakeLightFlasher1_zpsb5aac119.jpg.html)

Thinking about the mounting of this, (as it seems a bit of a vulnerable piece of equipment)  I am thinking about housing it in a box. Below is a small box purchased from Maplin today to house it. Should work well. Just a couple of holes drilled either end for the wires.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201312103rdBrakeLightFlasher2_zps6ee80ebb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201312103rdBrakeLightFlasher2_zps6ee80ebb.jpg.html)

VERY clever idea Paul, I've got one of these to fit myself and like the idea of mounting it in a box, Also, love the binder ends on the chequer plate!

Next keeping on the theme of cheap products from the high street. Next stop was Ryman the Stationers! WHAT??? I hear you ask? Basically for the exhaust hole cover I have got some chequered plate that I had to trim down each end. The cuts are not perfectly straight and the edges are very sharp so I thought about putting some trim on them. Rubber doesn’t really work as it is too flexible and the chequered parts make it sit up. So I thought out those black slide binder things you slide on A4 paper to hold a load of sheets together. The height of the chequered plate is 30cm as well (same as A4 paper) so used one of these on each end.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131210EdgingStrips1_zpsf38c191a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131210EdgingStrips1_zpsf38c191a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131210EdgingStrips2_zps2e4ce9f9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131210EdgingStrips2_zps2e4ce9f9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131210EdgingStrips3_zpsa5b765bc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131210EdgingStrips3_zpsa5b765bc.jpg.html)

I plan to paint the chequered plate all satin black at the end.

Here are the bits for the induction kit I plan to fit. These arrived today. This is the air feed that you need to fit an induction kit on the MR2. The MAF sensor sits in the hole.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131210InductionKit1_zps5a7e3457.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131210InductionKit1_zps5a7e3457.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131210InductionKit2_zps9270514c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131210InductionKit2_zps9270514c.jpg.html)

Here are the bits from the induction kit. I plan to fit it like Rudy has done in the wheel arch and have it connected to the pod by the petrol flap

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131210InductionKit3_zpsfae8d023.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131210InductionKit3_zpsfae8d023.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131210InductionKit4_zpsb89436a2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131210InductionKit4_zpsb89436a2.jpg.html)

Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 11, 2013, 07:43:42 AM
Also, yes, the Induction kit looks good!

Where did you buy it from?

Do you know of anywhere that sells sponges too? LOL  :D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 11, 2013, 08:47:30 AM
Cheers for comments guys.

Nice doorway Steve. My wife would love that in our house!

Cheets/Crossy, the induction kit is a universal one off ebay. It is very similar to the one Rudy got from car builder solutions. There is no point buying one specific to the MR2 as I am not going to mount it in the same way. The air feed pipe is needed though as the one on the MR2 is attached to the air box which needs to be removed.

Sponges??? I'm gonna buy you one for christmas!
Title: Re: Paul's 4thirty Build Diary
Post by: kalifornia on December 11, 2013, 09:17:09 AM
I.ve done that third brake mod.
I love it, and you can see people smile and point to it.

Keep up the good work and remember to use lockthread glue were ever you can, as the bolts and screws get a tendency to loosen sometimes as learnt the hard way.
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on December 11, 2013, 10:40:25 AM
In the spirit of recycling I just saw this

Enjoy

http://www.upworthy.com/watch-the-first-54-seconds-that-s-all-i-ask-you-ll-be-hooked-after-that-i-swear?c=reccon1

Title: Re: Paul's 4thirty Build Diary
Post by: seriph on December 11, 2013, 02:03:30 PM
Probably a totally dumb question but as it's impossible for me to see a DNA up close: are the upper (or lower I suppose) arch intakes a possibility for feeding air into the engine at all?

In my mind's eye I imagined the airboxes were fed by the two upper intakes but it's all covered by the side engine cowlings (or whetever they're called)  -  perhaps the MR2 configuration just doesn't lend itself to making the intakes functional in the same way ...
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on December 11, 2013, 02:13:22 PM
Paul I was also thinking about your mirror/garage width issue and can't help wondering if there might be a fold-in mirror setup that could be adapted  -  or maybe even spring for genuine mirrors, but then they're probably a king's ransom!

... just did a search and found that someone is making folding f430 style mirrors for all types of cars .... never knew!

:)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 11, 2013, 03:56:15 PM
Probably a totally dumb question but as it's impossible for me to see a DNA up close: are the upper (or lower I suppose) arch intakes a possibility for feeding air into the engine at all?

In my mind's eye I imagined the airboxes were fed by the two upper intakes but it's all covered by the side engine cowlings (or whetever they're called)  -  perhaps the MR2 configuration just doesn't lend itself to making the intakes functional in the same way ...

Yes mate. they are designed like this. In the kit there is a scoop that fits inside the hole at the top of the wing (which you have a grill over) and then there is a tube supplied that you can connect the scoop to the original MR2 air box. I am just changing it slightly to fit an induction kit (which isn't that much different really tbh) and I am having the filter mounted in the wing as opposed to the normal place on the MR2. I'll put a picture up in a second showing the pieces.
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 11, 2013, 04:26:09 PM
In the spirit of recycling I just saw this

Enjoy

http://www.upworthy.com/watch-the-first-54-seconds-that-s-all-i-ask-you-ll-be-hooked-after-that-i-swear?c=reccon1

That truly is amazing.......words fail me!


Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 11, 2013, 04:27:44 PM
Cheers for comments guys.

Nice doorway Steve. My wife would love that in our house!

Cheets/Crossy, the induction kit is a universal one off ebay. It is very similar to the one Rudy got from car builder solutions. There is no point buying one specific to the MR2 as I am not going to mount it in the same way. The air feed pipe is needed though as the one on the MR2 is attached to the air box which needs to be removed.

Yes, don't forget my SPONGE for Christmas Paul!!!  :) :) :)

Sponges??? I'm gonna buy you one for christmas!

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 11, 2013, 05:44:31 PM
This is for Steve  ;D

Below is the scoop hole on the top of the rear wing – circled below

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131211Induction1_zps17ef403a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131211Induction1_zps17ef403a.jpg.html)

This is how it will all fit together (I hope!)

Yellow arrow shows the scoop supplied in the kit that goes inside the wing and is bonded to the wing, with a grill over the top. Blue arrow shows some reducers. I put these in here just for the picture. In realilty this will be a longer hose. Then you have the induction kit with the filter enclosed in the cylinder and then a hose out the back of it. This is all attached to the car under the wheels arch. The hose out the back goes inside the engine and into the silver air feed that hold the MAF sensor (green arrow), which in turns goes into the engine (blue box). The yellow line is the structure of the internals of the car/wall what-ever you call it. I have drawn the wing/wheel arch in as well (sorry for the poor drawing)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131211Induction2_zps5d5c9abc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131211Induction2_zps5d5c9abc.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: cheets on December 11, 2013, 05:53:14 PM
Hi Paul

I hava had a look at the  induction kit  but were did you get The MAF sensor sits housing from ?
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on December 11, 2013, 06:07:10 PM
Paul I'm loving the induction kit mate really nice  :o
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 11, 2013, 06:16:26 PM
Hi Paul

I hava had a look at the  induction kit  but were did you get The MAF sensor sits housing from ?

Here you go.

http://www.eliseparts.com/products/show/41/725/toyota-air-feed/

Title: Re: Paul's 4thirty Build Diary
Post by: cheets on December 11, 2013, 06:28:26 PM
Thanks Paul :)
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on December 11, 2013, 09:37:17 PM
AHAH! Thanks mate  -  makes total sense now

:D

Title: Re: Paul's 4thirty Build Diary
Post by: steven on December 12, 2013, 08:03:17 AM
how will you deal with water ingress?? The scoops can take in quite a bit of water?
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on December 12, 2013, 08:15:29 AM
He's never going to wash it or take it out in the rain.that way it will be dry as a bone :)

Great details Paul coming along nicely :)

Don't forget to drill holes in the bottom of those scoops to drain any water like Steven says :)

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 12, 2013, 09:26:55 AM
haha, yes, i will try to refrain from driving it in the rain! But yes, I have always planned to drill drain holes in the bottom of the pods  - this should be enough. I will see how it goes and mointor the situation.. when i am on the road! yee ha!  8)
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on December 12, 2013, 09:48:06 AM
I wonder how the genuines handle it  -  I imagine a loop with a drain hole at the bottom would do the trick, IF there was room for it
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 13, 2013, 09:05:38 PM
I spent another 3 hours on the car last night. I managed to get the rear number plate and 3rd brake light wired up and started fitting the induction kit.


Rear Number Plate Lights

I added the extended wires to the original MR2 sockets located on the bumper bar and fitted the other ends into the bulb holders. These are very fiddly to fit. Note the angle the bulb sits in the holder. Almost at 45 degrees to the holder. Zip tied and tidied up wiring.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213NumberPLateLights3_zpscce5f1f2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213NumberPLateLights3_zpscce5f1f2.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213NumberPLateLights2_zpsdafba05b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213NumberPLateLights2_zpsdafba05b.jpg.html)


Bulbs aren't particularly bright so when I fit them for real I'll put in some brighter LED type ones.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213NumberPLateLights1_zpsc29c4bd6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213NumberPLateLights1_zpsc29c4bd6.jpg.html)


3rd Brake Light

As you know I have the flasher unit to fit and I thought about installing the flasher unit in a box to protect it. My initial location of where to locate the box wouldn't work as when the deck was closed the gas ram would hit it.

So decided on mounting it on inside of wing just behind the top of the suspension turret. (See photos)

Here is the box with holes drilled. The holes in the bottom of the box are for mounting it.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201312133rdBL1_zpsb758714a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201312133rdBL1_zpsb758714a.jpg.html)

The box is going to be mounted here

(http://i1315.photobucket.com/albums/t597/pjlucas1/201312133rdBL2_zpsb8468ef2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201312133rdBL2_zpsb8468ef2.jpg.html)

Here is the original MR2 third brake light wire. It is perfect length to just cut the white connector off and then connect straight to flasher unit.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201312133rdBL3_zps95e26d7d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201312133rdBL3_zps95e26d7d.jpg.html)

Here are all the ends stripped and flasher unit in situ.  Remember to have the flasher unit in the box and the wires through the box hole before you connect to original MR2 wire.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201312133rdBL4_zpsbabcdcf5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201312133rdBL4_zpsbabcdcf5.jpg.html)

Connected with heat shrink on. 

(http://i1315.photobucket.com/albums/t597/pjlucas1/201312133rdBL5_zps2b85d53f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201312133rdBL5_zps2b85d53f.jpg.html)

Then I wrapped all in amalgamation tape. Next I measured the wire to come out of the other side. I am running it under the top side of the rear clip and up through a hole at the back of the rear clip.

These are the connectors I used for the 3rd brake light. These are just normal electrical spades but the very small ones. I tried to find a proper socket on the web but couldn't.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201312133rdBL6_zps71ea4154.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201312133rdBL6_zps71ea4154.jpg.html)

So extended the wires the other end and wrapped all in amalgamation tape and fed through the car.

Here is the set up. Arrows point to the relevant wires. I have it going off under the rear clip at the arrow on the right.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201312133rdBL7_zpsb41e7841.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201312133rdBL7_zpsb41e7841.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201312133rdBL8_zpsef529d9d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201312133rdBL8_zpsef529d9d.jpg.html)

Here you can see the wiring from underneath. Yellow line is the direction of the wiring.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201312133rdBL9_zps36121552.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201312133rdBL9_zps36121552.jpg.html)

With the cover on

(http://i1315.photobucket.com/albums/t597/pjlucas1/201312133rdBL10_zps257053f3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201312133rdBL10_zps257053f3.jpg.html)

Then I connected wire to light. Sorry I don't have a picture of the wire coming thru the hole into light. Will get one at the weekend.

Here is a small video of it working.

(http://i1315.photobucket.com/albums/t597/pjlucas1/th_201312133rdbrakelight_zps555eb26b.jpg) (http://i1315.photobucket.com/albums/t597/pjlucas1/201312133rdbrakelight_zps555eb26b.mp4)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 13, 2013, 09:42:11 PM
Under Bonnet Cover

The plastic supplied in the kit, is just a rectangle piece and if you fit the plastic as it is, you’ll notice that there is a hole/gap here as there are bolts in the way that stops the plastic sliding up to cover the hole/gap.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Bonnet1_zpsb89ccc92.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Bonnet1_zpsb89ccc92.jpg.html)

I didn’t like this, so I cut out the correct areas in the plastic to allow it to be pushed further up and thus closing that hole seen. You could undo all the bolts and slid plastic underneath and drill through it, but then this would raise the under bonnet cover which I didn’t want.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Bonnet2_zpseced0e68.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Bonnet2_zpseced0e68.jpg.html)

I still haven’t fitting yet as it was too dark at the front of the car! But you get the idea.  ;D


Air Induction Kit

Firstly you need to remove the original air box set up. I recommended taking the car battery out as it gets in the way of one of the bolts that need’s to come undone. This is the pipe coming from the air box as standard. This would have been connected into another longer tube that would have connected to the MR2 side vent. This pipe will come off from the box with a slight twist and pull.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction1_zps601de892.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction1_zps601de892.jpg.html)

Unplug the MAF sensor and then undo the 2 small Philips screw holding it in. It should come out easily.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction2_zpsdb89dc04.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction2_zpsdb89dc04.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction3_zps4d0a7086.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction3_zps4d0a7086.jpg.html)

Here is what the MAF sensor looks like

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction4_zpsf5c6d52f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction4_zpsf5c6d52f.jpg.html)

Here is it removed

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction5_zps375ad824.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction5_zps375ad824.jpg.html)

To remove the top of the air box you need to undo the clip here, and the one on the other side of the MAF pipe. (yellow arrow) and then this bolt (green arrow).

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction6_zpsacba03fc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction6_zpsacba03fc.jpg.html)

The battery is removed in the picture below as this is the only way to get to this nut to undo it

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction7_zps811194c1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction7_zps811194c1.jpg.html)

Undo the hose clip the air box pipe is attached to  and then the air box lid should come out with a bit of persuasion (yellow arrow) Below are pictures with the lid off with air filter on show.  The lid has a pipe clipped to it, so unclip this first before you take the lid off. (green arrow)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction8_zpsa87a6b4d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction8_zpsa87a6b4d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction9_zpsdd9854e5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction9_zpsdd9854e5.jpg.html)

To remove the rest of the box, take out the filter and you’ll see this bolt that needs undoing (yellow circle). The box will come out. Again there is a pipe clipped to the box in 2 places, so pull the pipe away as you take the box out. (yellow arrow)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction10_zpscdb748e6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction10_zpscdb748e6.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction12_zpsc0aadff3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction12_zpsc0aadff3.jpg.html)

And here are the parts that you have just removed

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction11_zps23a437e8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction11_zps23a437e8.jpg.html)

Below is the empty space once the air box has been removed

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction13_zpse3303746.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction13_zpse3303746.jpg.html)


Below, I zipped tied one of the pipes that was clipped to the box previously to the car here to support it. (yellow circle)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction14_zpsf7d2ace2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction14_zpsf7d2ace2.jpg.html)

Added the silver MAF pipe

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction15_zpsbb846a6d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction15_zpsbb846a6d.jpg.html)

Added a reducer on the end of the silver pipe. This is a 65mm one. The hose in the kit would comfortably fit over the outside of the 65mm part of this, so I plan to cut the larger part off (see yellow dotted line) and the put the hose over this and secure with a hose clip.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction16_zps61af098f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction16_zps61af098f.jpg.html)

To mount the filter, inside the arch on the car structure there is this hole that I decided to use. This was already there on the car:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction17_zps3016f7d9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction17_zps3016f7d9.jpg.html)

Here is the filter with the support bracket. I bolted the bracket to the filter beforehand with a nut and bolt before attaching it to the car. Trying to do this with the nut whilst also attaching the filter to the car is very tricking as the clamp just tries to spring open. Bolted to the car like this seems sturdy enough.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction18_zps9f9af481.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction18_zps9f9af481.jpg.html)

I then attached the hose to it with a hose clip and mounted it under the wheel arch. I fed the hose back through into the engine bay. It is nice and far away from the exhaust but it is close to this white container.

***Question Guys*** what is this white container I have arrowed below and does it get hot?

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction19_zps48e086a0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction19_zps48e086a0.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction20_zps5a449e69.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction20_zps5a449e69.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction21_zpsbbdea531.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction21_zpsbbdea531.jpg.html)


Here is the view from looking inside the pod hole. Tight but should be able to get as hose on there..

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction22_zps4b82051a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction22_zps4b82051a.jpg.html)

Here is the hose ready to connect to the silver pipe. I had to stop there as I thought I’d need to buy a connecting pipe to join the two up. But I had the idea to trim down the reducer (see above) this morning on the train so will continue with it on Sunday and finish it off. Always good to sleep on things!!!  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131213Induction23_zps6cdcb6c7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131213Induction23_zps6cdcb6c7.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: sundog on December 14, 2013, 01:42:46 AM
Very nice description with pics ... fair play
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on December 14, 2013, 03:34:22 AM
Paul,

What is running into or out of the container  -  it looks like a vacuum reservoir but I guess that would be at odds with a modern vehicle
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on December 14, 2013, 06:42:01 PM
is it the expansion tank buddy ? looks like it

great details as always paul and a good build diary for future builders.

not long til paint :)
Title: Re: Paul's 4thirty Build Diary
Post by: NYAL F430 on December 14, 2013, 07:25:50 PM
hi, Paul great detail in your build, may go for the induction kit myself i was just wondering if the induction kit made any difference to the sound.

regards nyal
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 14, 2013, 08:15:27 PM
haha, yes, i will try to refrain from driving it in the rain! But yes, I have always planned to drill drain holes in the bottom of the pods  - this should be enough. I will see how it goes and mointor the situation.. when i am on the road! yee ha!  8)

Looks like you'll have to buy yourself a sponge as well as one for me for Christmas now mate!  :) :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 14, 2013, 08:43:46 PM
hi, Paul great detail in your build, may go for the induction kit myself i was just wondering if the induction kit made any difference to the sound.

regards nyal

Nyal, I haven't started the car up yet with the induction kit on. Will hopefully finish it off tomorrow and will try. It prob won't make much difference when the car is standing still. It will prob sound more when the car is movng and air is rushing into it. But we'll see. I just thought better to fit it when car is like this in case there were any fitting problems.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 15, 2013, 09:40:55 PM
7 Hours done today. Not the most productive but I did manage a few things

I finally finished the fit up of the induction kit. I’d like to say it was straight forward but it was a bit of a ball ache, mainly getting the hoses to fit and stay secure on the various pipes etc. but I got there in the end. I also chopped and changed the hose used from the silver air pipe. I tried using the DNA one but this didn’t work as it couldn’t be bent at tight enough angles so I went back to the supplied hose in the induction kit for that part, and then used the DNA one chopped done to connect the pod up to.

I also had to fiddle slightly with the mounting of the filter itself but managed to get it all lined up and the hoses not touching anything. Below are some pictures.

I chopped down the DNA hose here so it isn’t as long as below

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215Induction1_zpsb350c9f8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215Induction1_zpsb350c9f8.jpg.html)

Pod in place

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215Induction2_zpsd398c751.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215Induction2_zpsd398c751.jpg.html)

Arrow points to back of pod

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215Induction3_zpsba422dbf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215Induction3_zpsba422dbf.jpg.html)

Arrow points to front of car

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215Induction4_zpse1959fe5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215Induction4_zpse1959fe5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215Induction5_zps05e30692.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215Induction5_zps05e30692.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215Induction6_zps39d71371.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215Induction6_zps39d71371.jpg.html)

Zipped tied the hose back here

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215Induction7_zps3b016e57.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215Induction7_zps3b016e57.jpg.html)

I started up the car and had a listen. Nothing majorly different, but you can hear the sucking noises from the filter. Obviously the car is just standing still here. I’m sure once it starts moving and cold icy air is coming in as well it would sound a bit better. Here is a quick video of the sound.

(http://i1315.photobucket.com/albums/t597/pjlucas1/th_20131215InductionNoise_zps6ef4015a.jpg) (http://i1315.photobucket.com/albums/t597/pjlucas1/20131215InductionNoise_zps6ef4015a.mp4)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 15, 2013, 10:01:35 PM
Other jobs done today included starting taking bits off the car so they are cleared for painting.

Removed the 3rd brake light, and number plate holder and the side windows from the car (below)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215WindowsRemoved_zps62aeb24c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215WindowsRemoved_zps62aeb24c.jpg.html).

I am going to give the windows a good clean up and see if it can take them somewhere where the Toyota writing can be polished off somehow. Also tip for future builders, when you start to strip the MR2 I would take the windows out as well to prevent them getting damaged with angle grinders etc… I have a small chip on one of mine and a couple of specs which I don’t know how they got there. I enquired at Toyota and a new one is £99 + VAT so 2 news ones are out of the question really.

Also started building up the door cards.

Marked up with the door card on the car, where the arm rest would go, and drew a line in pen on the door card. I then drilled a hole in back of arm rest level with the handle hole and then placed back on car and marked a hole to drill in the card. Then I bolted them together tightly.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215DoorCard1_zps4415c20b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215DoorCard1_zps4415c20b.jpg.html)

Because I had done this, I could then drill from the back of the card through it and through the arm rest creating the other 2 fixing points at each end.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215DoorCard2_zps1cab4653.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215DoorCard2_zps1cab4653.jpg.html)

However the middle bolt if left visibly directly through the handle hole, will foul the handle when it goes in, so this will need to be removed and placed further backwards or forwards. TBH 2 bolts is probably enough anyhow, but I did another on further back

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215DoorCard3_zps00074c11.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215DoorCard3_zps00074c11.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215DoorCard4_zpsf7940185.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215DoorCard4_zpsf7940185.jpg.html)

The actual pocket, needs to be packed out for it to be flush with the rest of the door card

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215DoorCard5_zpsc070ddb0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215DoorCard5_zpsc070ddb0.jpg.html)

Drilled and bolted through the bottom

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215DoorCard6_zps4e0c4236.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215DoorCard6_zps4e0c4236.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215DoorCard7_zps9d541545.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215DoorCard7_zps9d541545.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215DoorCard9_zps26cf8a04.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215DoorCard9_zps26cf8a04.jpg.html)

***Question*** how to people secure these door pockets for the final fitting once covered? If I bolt it from just the bottom the pocket slopes backwards and is not flush at the side with the door card. Do people just stick the side pockets down when they are finally being fitted?

Door handle and surround

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215DoorCard10_zpsb8b60b38.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215DoorCard10_zpsb8b60b38.jpg.html)

Door handle cables. Unclip from both white clips circled

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215DoorCard12_zps2ec220cd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215DoorCard12_zps2ec220cd.jpg.html)

Slide door card on and then feed through cables through slit in door card

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215DoorCard13_zps842c5d4b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215DoorCard13_zps842c5d4b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215DoorCard14_zps826dd203.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215DoorCard14_zps826dd203.jpg.html)

To fit the handle to the cables, there is not much room to spare. However to make things easier if you slide the door card backwards out of position it makes more of the cables show and thus easier to fit to handle and when done slide card back forwards into position

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215DoorCard15_zps1da95f26.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215DoorCard15_zps1da95f26.jpg.html)

Handles sit up a bit as they are not tight in the hole. I plan to bond a piece of metal bracket in the arm rest so the handle can be screwed to it and thus not sit up and it will be more secure

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215DoorCard16_zpsdfb12c4e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215DoorCard16_zpsdfb12c4e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131215DoorCard17_zpsb9ba0cc3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131215DoorCard17_zpsb9ba0cc3.jpg.html)


 
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on December 15, 2013, 10:09:58 PM
Nicely done Paul nice cool air induction should sound great :)
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on December 15, 2013, 10:15:55 PM
looks great paul getting there with interior now.

 made some alloy brkts to hold the door handles in so you can screw them down.the cables are tight though ol bit of a stetch :) :)

keep up the good work mate
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 16, 2013, 12:05:35 PM
Hi Paul,

The side glasses you can buy replacements without the Toyota logo made by "Saint Gobain Glass" , not an issue if you are going to get your Toyota logo smoothed off but I think these cost out at about £75 each so cheaper than genuine Toyota. Might help future builders as an option if they break one or something.

Hey, hope your not using "my sponge" to clean everything down!! LOL  :D
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on December 16, 2013, 12:54:16 PM
same here crossy i had new door glasses and frt screen with new trim all supplied and fitted for £300 which i think is quite good they even fitted the rear deck glass for that too.

no toyota markings and the look of brand new...
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on December 16, 2013, 08:28:42 PM
me too
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on December 16, 2013, 08:38:27 PM
And me  :)
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on December 16, 2013, 11:05:28 PM
replacement glass sound like a better option than creating a potential stress point in the glass through reducing thickness. I may be way off of course, but I imagine this glass would be hardened safety glass which resists any form of tampering

Paul, a bracket of some description to hold the map pockets could add a really beautiful small detail  -  perhaps they could be fixed with black hex-head bolts to finish them off nicely....? Just a thought

NOTE: This is all being offered from someone who has NO physical access to the product or projects, so please forgive when my suggestions illustrate my ignorance

:)
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on December 16, 2013, 11:15:44 PM
Hi Paul

Just a suggestion when fitting the door arm rests they tend to be quite floppy when screwed to door trim so make a template and put some thin stainless or alloy inside the arm rest and some on rear of door trim.that way when bolted together you have metal on both sides of trim and handle and will be rock solid.or the fiberglass of arm rest will just flex if leaned on

Hope this helps buddy :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 19, 2013, 12:14:15 PM
cheers for the tips Wayne, will look into that. I've also thought about the actual closing of the door. you bascially pull it closed via the internal door handle. As this is connected to the door card only you are really just pulling the door closed via the door card only. the door card is only secured to the door metal round the edges of it.  this isn't great. i have read somewhere on this forum that someone had made a bracket that is bolted to the internal metal of the car in the centre of the door. as i need to make a bracket so the internal door handle can be screwed down, why not kill 2 birds with one stone and make a bracket that bolts to the metal of the door and then pokes through the door card and armrest and then you screwed down the handle to it.

in the picture below my idea is for an l-shaped bracket in yellow. not sure where to get the brackets from though? B&Q, Wickes? we'll see  ;), but this means now when you pull the door closed you are pulling somehting that is physcially attached to the door at this point as well..should be more secure. i just hope where i have drawn the bracket, it is in the right area for the internal door handle. anything further back then i am in toruble and there is no where to bolt the thing to...




Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 21, 2013, 05:53:31 PM
6 hours on the car today. Lots of little jobs done behind the scenes. These included:
•   Took front wheels off so now the car is all jacked up giving me better access all round
•   Adjusted the passenger rear exhaust tailpipe set up – I wasn’t happy before with how it sat but it is better now. I took off both tail pipes and put them away in preparation for painting.
•   I body filled in triangles in doors for inside of the door mirrors and also at the front of the door gaps. These are by no means perfect but it’s a start. Hopefully the body shop will make them better.
•   Gave the engine bay a lick of satin black. Again nothing to write home about but it doesn’t really matter that much. Maybe when I get the V6 put in I’ll get the engine bay painted properly LOL  ;D
•   On the upper scoops I drilled holes to drain the rain water out. I found the exact place by tipping a small amount of water into the pod and looked where it settled in a puddle and drilled there. Repeated for both sides.

Worked on the interior door handle set up:
I cut a slit in the door card where the bracket would slide through. Be generous with this slit giving you plenty of movement backwards and forwards as this will help when you put the door card on.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Door4_zps771b0d73.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Door4_zps771b0d73.jpg.html)

I used a 75mm angled bracket from Robert Dyas  ;D. On the metal of the MR2 the area where the bracket mounts is below. This is a dipped in the metal work. You need to remove the connector that is mounted in this sunken area (mounts via a clip into a hole in the metal). Sorry I don’t have pictures of it mounted before I took it off. Green arrow shows the hole where the original clip was held, thus mounting the connectors. Yellow circles are the connectors I am talking about. Yellow arrow is the hole I drilled to mount the door bracket.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Door1_zps1f4f3644.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Door1_zps1f4f3644.jpg.html)

The way I managed to get the bracket in the right space as a starting point is this:  Basically I used 3 strong circular magnets and put these on the internal metal of the door and then the bracket on tops of these. This way the bracket was stuck to the metal but could still be moved. I then put the door card on and then I could move the bracket to the right position with the door card on. When I was happy, I carefully removed the door card without moving the bracket and then I marked where it was, took it all off and then marked up the holes to drill. I drilled the centre one first and then bolted the bracket and tried it all out. I needed to re drill a hole in horizontal part of the bracket where the handle secures to (circle below), but apart from that there was no other adjustment needed really. Green arrow shows the wire that I have re-covered in amalgamation tape.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Door2_zpsdf5b9e52.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Door2_zpsdf5b9e52.jpg.html)

The grey connectors that where in the place where the bracket is now cannot go back in the same location. This is because the connectors are quite large and stick out a bit so would foul the door card when it was on. I solved this by re-routing it behind the metal of the internal door and securing with zip ties. Below photo shows what I mean – yellow dotted line

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Door3_zps79dc1eca.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Door3_zps79dc1eca.jpg.html)

Here is the re-routed wire from inside

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Door7_zpsdff3a413.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Door7_zpsdff3a413.jpg.html)

So then I put the door card on, connected up the wires to the handle and then placed into hole and secured down with a screw bolt. Might replace this with a countersunk Allen bolt later on.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Door5_zps7dfa3c35.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Door5_zps7dfa3c35.jpg.html)

View from underneath, handle secured.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Door6_zpsa7da9750.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Door6_zpsa7da9750.jpg.html)

So now when I pull the door closed from the inside using the handle I am pulling on something that is physically connected to the metal of the door. Closes very nicely and feels very secure.  I didn’t do the other door, as believe it or not, I ran out of nuts to secure the bracket with.  But I did manage to get the wiring re-routing done.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Door11_zps530e224c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Door11_zps530e224c.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on December 21, 2013, 06:28:03 PM
great work paul coming together nice,these little things take time.

also the triangle parts that you filled they always crack at that point as the filler cracks as the door moves.get the bodyshop to take out the fiberglass or filler and weld a plate across the hole then all it need is flexible sealer around the edge,i did this on mine and no cracks happened.the doors are very heavy and move alot which puts too much stress on that one point which unfortunatly cracks the filler.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 21, 2013, 06:32:34 PM
I took the dummy engine over again today and as I couldn’t do the other door I went about trying to fit this again. You may recall that last time I tried it, it sat up too much and thus the glass would therefore not fit flush. Well I looked into where it was fouling underneath and I’m afraid to say I have had to remove the mesh from the 2 outer parts. It also required some trimming down (see photos below) as there was some fouling on the strut braces. I didn’t fancy lowering the strut braces just for the fake engine, so I cut out a very small section of the engine instead. However all is not lost on the mesh. It looks pretty good without them. You can see right into the engine bay – on one side you can see the induction pipe I have fitted and on the other side you can see the Toyota writing on the engine cover, but I am sure I can come up with some way of disguising that!

Fouls here on each side:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Engine1_zpsc1742188.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Engine1_zpsc1742188.jpg.html)

Trimmed down

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Engine2_zps0a34c289.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Engine2_zps0a34c289.jpg.html)

Hinges mounted to exhaust-hole plate. I cut down my chequered plate at each end so the bonnet stops don’t touch it when the rear deck is closed.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Engine3_zps6316cbf1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Engine3_zps6316cbf1.jpg.html)

Toyota!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Engine4_zps797abed9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Engine4_zps797abed9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Engine5_zpse9bd299d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Engine5_zpse9bd299d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Engine6_zps395f10d2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Engine6_zps395f10d2.jpg.html)

Induction pipe showing through the gap

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Engine7_zps906cb880.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Engine7_zps906cb880.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Engine8_zps029820e5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Engine8_zps029820e5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Engine9_zps960effca.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Engine9_zps960effca.jpg.html)

I think I should have just about cleared the glass now! Will check at a later date
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 21, 2013, 07:05:12 PM
Like the door bracket Paul. Excellent idea and vgery clever using the magnets!

 :) :) :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 21, 2013, 07:26:53 PM
Beems, exactly which bits do you mean? The triangle part at the back of the mirror (red arrow) or the bit at the front of the door (green arrow)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221Door8_zps4848cff5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221Door8_zps4848cff5.jpg.html)

If it is the triangle, then there isn’t any metal to weld to there. The holes were only smallish and I have foam filled them first and the body fillered over the top. A plastic plate will be bonded over these anyhow when done. Or do you mean the front of the doors?

Finally, I took the air bag cover off the steering wheel.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221SteeringWheel1_zps31edd441.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221SteeringWheel1_zps31edd441.jpg.html)

But then I got stuck. I undid the nut in the middle, but how do I get the rest of the steering wheel to come off? It won’t budge. Is a special tool needed at the below arrow points

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221SteeringWheel2_zps4680ca15.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221SteeringWheel2_zps4680ca15.jpg.html)

So that’s it really for the year. (Might sneak an update in before 2014, we’ll see). I have started to take bits off the car as I build and fit them in preparation for when it gets painted. Her she is with her Christmas coat on and looking a bit naked in the rear end department! LOL

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221End_zps332511dc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221End_zps332511dc.jpg.html)

I’d just like to say thanks to everyone for their help/advice and great words of encouragement this year. Looking forward to 2014 as the car should be done and I will get to meet hopefully some, if not all of you at a show in 2014. Merry Christmas and a Happy New Year to you all.  ;D

Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on December 21, 2013, 08:02:16 PM
The green one buddy :) we're its smoothed in.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 21, 2013, 09:22:04 PM
Found out about the steering wheel. Need to buy a steering wheel puller.  Also found a guide on the web on removing the wheel:

http://spyderchat.com/forums/showthread.php?39028-How-To-Install-an-Aftermarket-Steering-Wheel-%28COMPLETE%21%29

Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on December 21, 2013, 10:43:48 PM
 :D thanks for the journey paul its been great to have been along for the ride happy Christmas and a Happy New year pal
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on December 21, 2013, 11:25:46 PM
Dont buy a puller, I made one out of angle iron. Pm your address and I will post it. Or simply make one
MADMAN
Title: Re: Paul's 4thirty Build Diary
Post by: cheets on December 21, 2013, 11:52:09 PM
Well Paul thanks for your Build Diary as it is going to help me so much bout think my one will be as detailed as what your doing but if i do anything different i will let you all know :)

Cheets

Marry Christmas to you all  ;)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on December 22, 2013, 08:01:39 PM
dont need a puller mate just kerp tapping on the wheel from the back with a rubber mallet...mine just came loose after tapping in about 3 different positions....
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 22, 2013, 08:24:33 PM
Cheers Phil. Might give that a try first then.
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 22, 2013, 09:22:20 PM
Paul,

I've took a few MR2 Steering wheels off, if you just give it a good even thump each side from the back with each hand (at the same time) it should come off. Or as Madman says use a mallet and tap it round.

Sometimes a good old pull will do it (watch your teeth though) if it suddenly comes off. You must just have a stubborn one. Maybe a squirt of wd40 down the splines.  :)
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on December 22, 2013, 09:34:14 PM
a mate of mine did that a fews years ago pulling the steering wheel off he broke his nose :) he was a boxer so was probally used to it.
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 23, 2013, 02:15:10 PM
Surprised he owned up to that! LOL :)
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 23, 2013, 02:17:05 PM
Maybe worth putting a gum shield in first Paul before trying my method or maybe Madmans idea is a better option!!  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on December 24, 2013, 07:48:16 AM
Leave the nut on the last few threads so the wheel can't suddenly come off and hit you in the face, then wiggle and pull and hit the edge of the rim from front and rear several times, it'll break loose and come off the splines without breaking your face.

Beany  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 24, 2013, 02:48:26 PM
Cheers for all your advice guys. That's what makes this forum so great. Might give it a quick try tomorrow when I collect Dad. Happy Christmas to all of you.. and finally here is a picture of my latest building work: A wall of beer ready for the big day! 
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on December 24, 2013, 04:27:42 PM
merry xmas buddy have a good one :)
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on December 25, 2013, 03:35:39 PM
A few lubricant-filled induction pipe sections in there I see. If you taped the glass reduced to the blue and gold aluminium pipe ......

:)

Merry Christmas mate. Have a safe one filled with love
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 25, 2013, 03:56:22 PM
Cheers everyone. Please to report the steering wheel was removed Xmas day at 11am with no blood spilt. Cheers!  8)
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on December 25, 2013, 10:06:25 PM
Removed on Christmas Day huh?

I believe I speak for everyone when I say, when we see a picture of your snoz, we'll decide if blood was shed.

:)))

Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 26, 2013, 10:08:34 AM
Well done Paul! But that's determination working on your car on Christmas day though!!! Hope you managed to get through that wall of beers! LOL  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 26, 2013, 10:41:27 PM
Here’s a quick update on the things I have been working on in between making a dent in that wall of beers I have in my fridge!

Rear Arch Liners

Started looking into these last time I was at the car, and my advice is this – don’t even bother trying to fit them without bending the tabs back first. You will not get anywhere as it is like trying to put a duvet in its cover with your feet! Thanks to Rudy for his advice on heating up the tabs and then bending them. Use the guide Rudy has posted in the owners section to identify which liner is which

Here are the rear liners. They are handed. The arrow below points to the front of the car. The tabs attach to the inside of the arch against the metal body work. The liners I have, have a plastic covering on them (blue writing) which when I fit for the final time, I will remove. For now I am leaving on to protect them.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221ArchLiner1_zpsf8c316e3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221ArchLiner1_zpsf8c316e3.jpg.html)

To bend the tabs, I scored them first to help them bend in the correct place.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221ArchLiner2_zpsdd36c645.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221ArchLiner2_zpsdd36c645.jpg.html)

Then use a heat guy to warm the scored section, and bend them up and hold in place till it cools.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221ArchLiner3_zps8aede050.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221ArchLiner3_zps8aede050.jpg.html)

Take each tab in turn

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221ArchLiner4_zps04aca551.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221ArchLiner4_zps04aca551.jpg.html)

It will take no longer than 10 minutes per liner to do this, but will save you loads of bother when fitting later.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131221ArchLiner5_zps15216b87.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131221ArchLiner5_zps15216b87.jpg.html)

I have refrained from pre-drilling holes in the tabs for now until I have seen how it all fits up when I get to the car again
Title: Re: Paul's 4thirty Build Diary
Post by: cheets on December 26, 2013, 10:45:58 PM
Like it
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 26, 2013, 11:03:08 PM
As said before I managed to remove the steering wheel on Christmas day in the end. Thanks again for all the advice I received on the subject. In then end all that was needed was a few wallops with a rubber mallet and it came free quite easily in the end.
Here’s the wheel once removed from the car

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131226SteeringWheel1_zpsef6c741e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131226SteeringWheel1_zpsef6c741e.jpg.html)

These are the bolts you undo to remove the air bag cover prior to removing the wheel. Note that these are designed not to fall out, so when you loosen them for the first time they’ll eventually just spin and spin but won’t hold be holding the air bag anymore.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131226SteeringWheel2_zpsdf69ed57.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131226SteeringWheel2_zpsdf69ed57.jpg.html)

Undo these screws to remove the back part of the MR2 steering wheel

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131226SteeringWheel3_zps3aab5f6c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131226SteeringWheel3_zps3aab5f6c.jpg.html)

This metal part also needs to be removed

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131226SteeringWheel4_zps92f6f26d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131226SteeringWheel4_zps92f6f26d.jpg.html)

It is held in place via force via the springs below.  These springs enable the air bag to move at the side for the MR2 horn push

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131226SteeringWheel6_zps133b1ade.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131226SteeringWheel6_zps133b1ade.jpg.html)

These are the pieces that you get in the kit

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131226SteeringWheel5_zps0b1ac21a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131226SteeringWheel5_zps0b1ac21a.jpg.html)

A is the front plate – I will spray this silver like the original F430 wheel. B is the rear part of the steering wheel. C is the part that goes on A and holds the push horn button.

You’ll need to buy a starter button and horn button – both available on eBay. I planned to cover C in leather look vinyl, however this part is textured like leather anyway so I may just spray it first and see how this comes out. Brackets will need to be fabricated to bolt C to A. A seems to fit and stay within the spokes of the steering wheel on its own but I may also create a bracket to at least have it bolted down as well.

Here is B mounted into the original wheel. You secure it via the same way the MR2 part was.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131226SteeringWheel7_zpse555047a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131226SteeringWheel7_zpse555047a.jpg.html)

Here is A and C together, along with the Manettino fake switch and sticker supplied by DNA.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131226SteeringWheel8_zps77f10040.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131226SteeringWheel8_zps77f10040.jpg.html)

Hole just drilled and bolted from the underside for the Manettino switch

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131226SteeringWheel9_zps7c7e4fd8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131226SteeringWheel9_zps7c7e4fd8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131226SteeringWheel10_zps5b6d9309.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131226SteeringWheel10_zps5b6d9309.jpg.html)

Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on December 27, 2013, 11:40:04 AM
 :)nice work as usual Paul very detailed build thread thanks  ;D ;D
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 29, 2013, 09:35:10 AM
Paul, I just realised the thicker arch liners have a textured finish whilst the thinner arch liners have a smooth shiny finish (on both sides). I don't know what others opinions are but the thinner type are easier to fit without the need for too much work with the heat gun.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 29, 2013, 02:17:45 PM
Total Build Time: 254 Hours

Got a few jobs done over the festive period:

Rear pod grills. Marked up and cut out templates for them.

DNA advised to do it this way as you want to ensure that the grill pattern is in the right position – more like a diamond shape running down from top to bottom. If you cut out the grills without having done this first you may cut the grill in such a way that when it is fitted the grill pattern is more square-like as opposed to a diamond shape when you look at it.
It is better to do it this way as when the pods are on the car, they are twisted slightly, thus making the grill pattern move out of position ever so slightly.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131227Pods1_zpsd797e186.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131227Pods1_zpsd797e186.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131227Pods2_zpsdd5be762.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131227Pods2_zpsdd5be762.jpg.html)

Holding the pod face on towards you

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131227Pods3_zps31c14c6c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131227Pods3_zps31c14c6c.jpg.html)

But when the pod is attached to the car it is positioned more like this

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131227Pods4_zpsfed23a12.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131227Pods4_zpsfed23a12.jpg.html)

Pod in place, and then I drew some rough lines of how I wanted the grill to look. Then you can position and cut the grill accordingly away from the car.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228Grill_zpsbe4eae91.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228Grill_zpsbe4eae91.jpg.html)

On the steering wheel I wasn’t happy how the rear part fitted onto the MR2 wheel, so I filled and re-shaped them

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131227SteeringWheel1_zpsd66a858a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131227SteeringWheel1_zpsd66a858a.jpg.html)

Fits better than it did

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131227SteeringWheel2_zps35dd369d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131227SteeringWheel2_zps35dd369d.jpg.html)

Drilled hole for horn button

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131227SteeringWheel3_zps02d33de9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131227SteeringWheel3_zps02d33de9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131227SteeringWheel4_zpsbb400a21.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131227SteeringWheel4_zpsbb400a21.jpg.html)

Starting to take shape

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131227SteeringWheel5_zpse5d526c6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131227SteeringWheel5_zpse5d526c6.jpg.html)

Also on the door cards, cut out grills for the speaker covers. I am not going to bother with separate tweeters like in the MR2, and put in some Sony 2-ways that I have here. Going for the stealth look though, so once the door cards are covered, I will bond the grill behind like below to hide the actual speakers. Will put some cloth to make the grill less see-through.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131227SpeakerGrill1_zpsf9fadec8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131227SpeakerGrill1_zpsf9fadec8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131227SpeakerGrill2_zps032ccac9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131227SpeakerGrill2_zps032ccac9.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: miata_fanatic on December 29, 2013, 03:45:38 PM
Congrats for the level of detail you put in that car!!
Can't wait to see it finished!!!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 29, 2013, 08:54:52 PM
Next was adding the furniture connection blocks to the inside of the wheels arches to add some height

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228ArchBlocks1_zps9d23694b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228ArchBlocks1_zps9d23694b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228ArchBlocks2_zps419ff9cc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228ArchBlocks2_zps419ff9cc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228ArchBlocks3_zpsf5ea4ca3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228ArchBlocks3_zpsf5ea4ca3.jpg.html)

I think I added about 5 or 6 to each wheel arch.

Next, I removed the instrument panel. After removing the steering wheel, I undid these screws

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228InstrumentCluster1_zps3aaf91a1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228InstrumentCluster1_zps3aaf91a1.jpg.html)

Then the top part is held via clip inside in in the short of shape in like the above triangle as well as screws at the arrow

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228InstrumentCluster2_zpsb93969a8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228InstrumentCluster2_zpsb93969a8.jpg.html)

I just loosened this part. I didn’t need to fully take it away

The instrument cover just unclips from the bottom and comes out

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228InstrumentCluster3_zps98ca2e88.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228InstrumentCluster3_zps98ca2e88.jpg.html)

Then the actual cluster is held by 3 screws

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228InstrumentCluster4_zps0b3e1336.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228InstrumentCluster4_zps0b3e1336.jpg.html)

There are 3 connectors at the back. They don’t need labelling up as they are all different shapes. The clips are a bit fiddly so don’t force them. It isn’t help by the fact you are restricted because of the wires and the windscreen in the way. A small flat head screw drivers helps release the clips, but as said before, don't force anything otherwise they’ll break

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228InstrumentCluster5_zpsdea07a47.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228InstrumentCluster5_zpsdea07a47.jpg.html)

Removed

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228InstrumentCluster7_zps03049616.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228InstrumentCluster7_zps03049616.jpg.html)

I removed this now as I have new dials to add to them, which can be done away from the car in front of the TV sometime later. They instrument cluster can be added back once the car is nearly done.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 29, 2013, 09:27:22 PM
Thinking ahead here for when the time comes to fit the headlights, I started to look at the available access in this area knowing it was going to be fiddly. I made my headlight unit up and taped protective film over the cover to protect it and then fitted it into the car.  The whole unit can fit into the car via the actual headlight hole from the front of the car and then you can re-position it accordingly. This was the first time I had tried it and the lens fits the hole nicely

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228Headlight1_zps3a2b63a8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228Headlight1_zps3a2b63a8.jpg.html)

This is the view from inside the wheel arch

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228Headlight2_zpse3767974.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228Headlight2_zpse3767974.jpg.html)

This piece of metal I have labelled with the green arrow, doesn’t seem to serve any purpose than to get in the way. I think it used to be a supporting bracket for the MR2 wings. It is just pop-riveted on with 3 rivets I have labelled with the yellow arrows

This is the view of the piece from the front on both sides of the car

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228Headlight3_zps58ec2ff9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228Headlight3_zps58ec2ff9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228Headlight4_zps2d1b8783.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228Headlight4_zps2d1b8783.jpg.html)

I just drilled out the rivets and then the piece came away.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228Headlight5_zps82dbc8b0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228Headlight5_zps82dbc8b0.jpg.html)

From inside the wheel arch: Looks like much better access to the light set up now. I thought I would need to angle grind this piece off, so wanted to avoid doing it when the car was painted, but now it is a lot simpler to remove the piece by drilling out the rivets

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228Headlight6_zps377d787a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228Headlight6_zps377d787a.jpg.html)

This is the piece that comes away

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228Headlight7_zpsfee86004.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228Headlight7_zpsfee86004.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 29, 2013, 09:52:56 PM
I added some draught excluder to the gaps on the rear decks/pods to see what it would look like once rubber trim was in there to help be with the lining up of the pods. I think this is one think part of the build that you can never really truly get 100% in line. I used 3mm draught excluder and doubled it up in places.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228Pods1_zps67ecd1b0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228Pods1_zps67ecd1b0.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228Pods2_zps8a82ad36.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228Pods2_zps8a82ad36.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228Pods3_zps2f96401b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228Pods3_zps2f96401b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228Pods4_zpsf34e8983.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228Pods4_zpsf34e8983.jpg.html)

I just wanted to see how various parts would lie/sit with the trim/gaps filled in.

Also looked at the surrounds that go in the exhaust tailpipe holes. These have a large return on them that I found needed to have a lot cut away for them to sit better

Here are the originals

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228ExhaustSurrounds1_zpsbf83bc22.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228ExhaustSurrounds1_zpsbf83bc22.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228ExhaustSurrounds2_zpscb9c7f74.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228ExhaustSurrounds2_zpscb9c7f74.jpg.html)

Fitted

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228ExhaustSurrounds3_zps80395978.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228ExhaustSurrounds3_zps80395978.jpg.html)

Now the trimmed items

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228ExhaustSurrounds4_zpsf0c3800d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228ExhaustSurrounds4_zpsf0c3800d.jpg.html)

Also did more work on the door cards…

Fitted up the bracket for the driver’s door interior handle to screw down into thus pulling on the metal work of the door itself when closing the door from the inside not just the door card.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228Door1_zps3038f280.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228Door1_zps3038f280.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228Door2_zps912311bf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228Door2_zps912311bf.jpg.html)

Then I noticed something on the door car fit up that might cause a problem to future builders. Here’s the story: Dad did the initial fit up of the door cards ages ago and when he did that, the windows were fully down. This is normal I guess, but last week I took the actual windows out. No dramas there, but of course to take the windows out they were up. This means that the glide rail/motor thing that the makes the windows go up and down was in the fully up position. Then I noticed that the top of the door card fouled it. See this in the picture below. Arrow points to the edge of the door car and the thing that hits the door card is the white piece of plastic. 

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228Door3_zpse1381518.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228Door3_zpse1381518.jpg.html)

Now I don’t know that if in reality the window motor thing goes quite all the way up when the window is in etc... But I am not taking any chances so I ground away the door card so there was no fouling. I know the picture isn’t great but it now clears it. There is no lip at all on this part of the door card now

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131228Door4_zps2f46504b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131228Door4_zps2f46504b.jpg.html)

I think that will do for now! Back to work tomorrow! Boo!  :(
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on December 29, 2013, 11:42:43 PM
Looking good mate. Great build.
One tip. Double up on the modesty blocks. Put two on top of each other and bond them in.
I found that with only one the wheels rubbed sometimes but by putting two it cured it.
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on December 30, 2013, 02:58:57 AM
Great work as ever mate. Definitely pleased to. See the stealth option on the speakers. Only way to approximate a strong proprietary appearance I reckon.

Is the horn button factory or rep? The wheel is lookin brilliant.
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on December 30, 2013, 09:44:45 AM
Another great write up Paul! You must have got a good day in (and long day) yesterday!  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on December 30, 2013, 10:34:16 PM
Cheers for comments guys. Steve - not sure on the horn button. I went in on a group buy Phil was doing. Wasn't  too much money so probably a replica.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 01, 2014, 08:10:31 PM
Firstly, Happy New Year to everyone on this great forum! I hope you all had good new-year celebrations. I woke up with a banging head ache and I thought the best way to cure it would be to get the jigsaw out and work on my door speakers!

Below on the left, is the standard MR2 door speaker and the one on the right is the Sony speakers I want to use. You can see the MR2 speaker has the mounting points built in to it. Therefore to use standard round speakers I needed to cut out the similar shape out of MDF to mount them in.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101Speakers1_zps4944d5cd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101Speakers1_zps4944d5cd.jpg.html)

Here is the MDF mounting plates

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101Speakers2_zps74a9e567.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101Speakers2_zps74a9e567.jpg.html)

Holes cut

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101Speakers3_zps6785efae.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101Speakers3_zps6785efae.jpg.html)

Speaker mounted. It doesn't protrude any further backwards than the original did and the surface of the speaker should clear the door card as well.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101Speakers4_zpsc0da46d8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101Speakers4_zpsc0da46d8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101Speakers5_zps07396f58.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101Speakers5_zps07396f58.jpg.html)


Door card pockets.

I thought I'd revisit this and see if I could get any further with attaching these. Previously I'd planned to bolt through the bottom of the pocket but that would mean bolts on show and also didn't solve the issue of securing the top parts of the pockets. A quick text to Sir Rudy (cheers Mate!) asking what he did yielded the result of bonding bolts to the inside of the pockets. So here goes…

I drilled 4 holes here on the door card

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101DoorCard1_zps871915a5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101DoorCard1_zps871915a5.jpg.html)

Then I fitted bolts and used nuts and washers to get the fit of the pocket just right as packing out is also required. I used washers as big as possible where I could to allow for as much of the area to be bonded to the pocket.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101DoorCard2_zps432a21ee.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101DoorCard2_zps432a21ee.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101DoorCard3_zps19aaa9d1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101DoorCard3_zps19aaa9d1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101DoorCard4_zps0fab0dee.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101DoorCard4_zps0fab0dee.jpg.html)

Then I put blobs of bonding agent on the nuts/washers and put the pocket on and stuck down and waited for it to set. This is just to get the position correct. You can add more sealant for strength later once you have removed the door pocket

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101DoorCard5_zpsb0ba7a3e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101DoorCard5_zpsb0ba7a3e.jpg.html)

This is the view from the other side

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101DoorCard6_zps70c70921.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101DoorCard6_zps70c70921.jpg.html)

Here I have removed the pocket and then added more sealant all over the washers and left to set

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101DoorCard7_zps6ce9e0c4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101DoorCard7_zps6ce9e0c4.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101DoorCard8_zps5e831e82.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101DoorCard8_zps5e831e82.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101DoorCard9_zps94487c96.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101DoorCard9_zps94487c96.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101DoorCard10_zpse5b96271.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101DoorCard10_zpse5b96271.jpg.html)


Also made some brackets to hold the front part of the steering wheel.

The metal here was off eBay and is nice as it is thin enough to bend as you want.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101SteeringWheel1_zps035ab7a2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101SteeringWheel1_zps035ab7a2.jpg.html)

Made a bracket like this

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101SteeringWheel2_zps8be8da85.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101SteeringWheel2_zps8be8da85.jpg.html)

Bonded in place and then can be screwed to the plate.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101SteeringWheel3_zps91f0e335.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101SteeringWheel3_zps91f0e335.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140101SteeringWheel4_zps7557b291.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140101SteeringWheel4_zps7557b291.jpg.html)

Headache now finally gone!!!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on January 01, 2014, 08:30:41 PM
 ;) certainly beats feeling sorry for yourself all morning well done Paul your building a great car have a great new year you deserve it ;D
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on January 01, 2014, 09:18:27 PM
Great. Work Paul and a great build diary.

Exactly the same speaker mdf housings I made and horn push plate Brits.

Great minds eh buddy :)

Keep them coming
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 01, 2014, 09:27:37 PM
Cheers Ghall very kind. Wayne, I have to confess I nicked those ideas from your build diary. But I'm sure you won't mind.   ;D
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on January 01, 2014, 09:45:49 PM
And the build goes on!

Lovely work as ever.


A question for everyone:  

I'm wondering if the mr2 ever had a variant with in-car adjustable suspension. I recall some chariot I drive years ago that I could dial the ride firmness up or down.

Maybe such systems are available aftermarket?


The reason I ask is because of that red switch on the steering wheel which appears to do nothing, could possibly be set up to function.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 01, 2014, 10:06:14 PM
Don't know about that suspension variant but the switch on the wheel is fake so won't be able to do anything. Phil is thinking about installing the Manetino switch get comes off the ferarri computer gaming wheel which is a proper switch that could be made to function.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 03, 2014, 09:02:56 AM
Morning Guys

Before I forget this, could some one possibly help me in telling exactly where on the roll bar carrier i need to cut the 2 slots that are needed for the roof straps that pull down the roof? I know on Beemaman's diary p44 there is talk about them but can anyone give me some measurements from a fixed point etc? Other photos if poss  ;D Do the straps go down between the gap between the rear of the roll bar carrier and the rear deck from the top and then poke through the bottom of the roll bar carrier? I guess they are hidden inside the glove boxes? Looking at beem's p44, looks like the slots are cut at the bottom of the carrier do they don't show whent he gloves boxes are closed. Below is a photo of what i am talking about. thanks in adavcne for your help

Title: Re: Paul's 4thirty Build Diary
Post by: crossy on January 03, 2014, 09:14:07 AM
I'll take some photos for you mate and some measurements. Give me half an hour and I'll post on for you  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 03, 2014, 09:22:47 AM
Cheers Chris, you're a star!
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on January 03, 2014, 09:42:32 AM
The measurement of the strap that comes through the slot is 25mm. The slot I cut out I've measured at 38mm long x 6mm wide and this works fine as per picture below:-
[(http://i1329.photobucket.com/albums/w542/siestasunbeds/hood_straps1_zps39a9792d.jpg) (http://s1329.photobucket.com/user/siestasunbeds/media/hood_straps1_zps39a9792d.jpg.html)][/img]

more to follow in a minute!
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on January 03, 2014, 09:48:10 AM
The photo I took is of the passenger side so you will notice that the position of the slot is just to the right of the storage bin door locking pieces. I've measured for you as well from the right hand edge of the whole section so you can use that as a datum point. As per picture below,

[(http://i1329.photobucket.com/albums/w542/siestasunbeds/hood_straps3_zps37dbc255.jpg) (http://s1329.photobucket.com/user/siestasunbeds/media/hood_straps3_zps37dbc255.jpg.html)][/img]

You will see its around 245mm/250mm from this edge. I'll send another picture in a minute of a further out view so you can see where I've measured from.
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on January 03, 2014, 09:51:03 AM
This picture shows where I've measured from

[(http://i1329.photobucket.com/albums/w542/siestasunbeds/hood_straps2_zpsa8b9dad5.jpg) (http://s1329.photobucket.com/user/siestasunbeds/media/hood_straps2_zpsa8b9dad5.jpg.html)][/img]

In summary then, the slot is just to the right of the storage bin catch and approx. 245-250mm from the edge as shown in the picture above.
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on January 03, 2014, 09:52:00 AM
If you need any more pics or measurements Paul just let me know  :)
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on January 03, 2014, 09:54:21 AM
Meant to add, did you notice I'd cleaned the car? !!!  Got a bit of Clio dust on it now from my daughters car so will need another going over with the sponge once hers is done which should hopefully be today!  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 03, 2014, 10:04:17 AM
Awesome, thanks very much Chris. Good work on cleaning the car. Seems the sponge worked well. Now, as you have the camera out we all want to see some full shot pictures of your car - for inspiration for me!!!
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on January 03, 2014, 06:40:20 PM
Yes Paul will get some full shot pictures up soon, need to get one headlight adjusted before refitting the front bumper and a few minor trimming to the bolts on my dummy calipers so I can get my wheels back on to make the car look respectable.

My daughters car will be all finished tomorrow so then hoping to have a good garage clean up and then back to work on my car!

Yes, sponge came in handy though!!!

Also need to sell a couple of MR2's that I don't seem to be able to give away at the minute! :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 04, 2014, 07:18:39 PM
Another 7 hours done in this delightful UK weather. Here’s what I got up to…

Started on fitting the door speakers – added the wood templates I had made at home. Had to use longer bolts to attach them to the door

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104DoorSpeaker1_zps93304470.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104DoorSpeaker1_zps93304470.jpg.html)

These are the MR2 wires. Arrow points to the main speaker one (not the tweeter)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104DoorSpeaker2_zpsb26c1caf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104DoorSpeaker2_zpsb26c1caf.jpg.html)

Don’t be tempted to cut off the tweeter connector if you’re not using it. It seems the wires go into this and out again and cutting it would disconnect the main speaker wire

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104DoorSpeaker3_zpsfacac799.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104DoorSpeaker3_zpsfacac799.jpg.html)

Added the normal audio connectors and wrapped in amalgamation tape

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104DoorSpeaker4_zps7b4f4410.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104DoorSpeaker4_zps7b4f4410.jpg.html)

Speaker installed. Arrow points to tweeter connection strapped out of the way

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104DoorSpeaker5_zps33d8deeb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104DoorSpeaker5_zps33d8deeb.jpg.html)

Door card doesn’t touch speaker at all.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104DoorSpeaker6_zps87d10ccb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104DoorSpeaker6_zps87d10ccb.jpg.html)

Other side done

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104DoorSpeaker7_zps30bd2d21.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104DoorSpeaker7_zps30bd2d21.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104DoorSpeaker8_zps271ea649.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104DoorSpeaker8_zps271ea649.jpg.html)

I think I will paint the MDF satin black to avoid it showing through the grill I add to the door card later.


On the steering wheel, as the rear part didn’t sit as flush against the MR2 factory wheel as before, I was concerned that there could be some rubbing when the wheel was turned. Arrow shows the slight gap between MR2 grey part and DNA part.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104SteeringWheel3_zps97651291.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104SteeringWheel3_zps97651291.jpg.html)

Putting the wheel on however, there seemed to be no catching, so I think we are cool.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104SteeringWheel1_zpsa80d1047.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104SteeringWheel1_zpsa80d1047.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104SteeringWheel2_zps3fbc643b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104SteeringWheel2_zps3fbc643b.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 04, 2014, 07:41:18 PM
Removed the roll bars and put away for trimming later. Then I tidied up the holes where the roll bars go

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RollBarCover1_zpsbbe22490.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RollBarCover1_zpsbbe22490.jpg.html)

Next I marked up where to cut the slots for the roof straps. (Thanks again Crossy for all the measurements you gave me). I did plan to do this with the cover on the car, but it is a lot easier with it off. LOL .

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RollBarCover2_zps65828482.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RollBarCover2_zps65828482.jpg.html)

Slots cut

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RollBarCover3_zpsa80170b7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RollBarCover3_zpsa80170b7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RollBarCover4_zps4603af15.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RollBarCover4_zps4603af15.jpg.html)

From the other side

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RollBarCover5_zps93bfc9b9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RollBarCover5_zps93bfc9b9.jpg.html)

Back on the car

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RollBarCover6_zpse8bbe862.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RollBarCover6_zpse8bbe862.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RollBarCover7_zpse29af172.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RollBarCover7_zpse29af172.jpg.html)


I wanted to the secure the sill at the rear of the car more, and I spied on Beemaman’s build a piece of metal connect the original car and the sill.

I noticed an original fixing point here on the MR2. I guess this held part of the original body work. It has a welded nut, on it so I thought I’d bolt a metal bracket to it and form a solid connection to secure the sill.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104SillBracket1_zps345c4f29.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104SillBracket1_zps345c4f29.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104SillBracket2_zps7c6b3406.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104SillBracket2_zps7c6b3406.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104SillBracket3_zpseda0d4f6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104SillBracket3_zpseda0d4f6.jpg.html)

Added another nut as well

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104SillBracket4_zpscec199c8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104SillBracket4_zpscec199c8.jpg.html)

Other side

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104SillBracket5_zpsd4f24339.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104SillBracket5_zpsd4f24339.jpg.html)

The sills are rock solid now
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on January 04, 2014, 08:09:59 PM
Nice work again Paul! Must be the 5.a.m. start! The extra support on the sill is a good idea.  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 04, 2014, 09:12:25 PM
Next was the rear diffuser. Hadn’t looked at this for a long time, last time was before I had bonded on the rear deck! 6 months ago!  I fitted it back and had a long how things stood. Very pleased with the result.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser1_zpse1f54af8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser1_zpse1f54af8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser2_zps21360c72.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser2_zps21360c72.jpg.html)

Next I added the brackets supplied by DNA to the top of the diffuser. These are designed to stop the diffuser sagging in the middle by hooking onto the return on the inside of the rear bumper. The hole in the bracket is actually threaded as well. Nice.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser3_zps55c310bb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser3_zps55c310bb.jpg.html)

I put one roughly where I wanted it to go and drilled a hole. Drill from the inside as it is easier. I just measured a distance (9/10cm approx.) from the fixed point of the edge of grill hole.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser4_zpsfc6abac1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser4_zpsfc6abac1.jpg.html)

Then did the same distance the other side so they matched

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser5_zps6ea6c2f1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser5_zps6ea6c2f1.jpg.html)

Used Allen bolts with washers to secure them.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser6_zps177a3053.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser6_zps177a3053.jpg.html)

Placed back on the car you can see how the brackets hook over

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser7_zpse9059b5e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser7_zpse9059b5e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser9_zps01178720.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser9_zps01178720.jpg.html)

They don’t touch quite enough so I will pack out the return lip so they do.

Below are the bolts that go through the diffuser and then the return of the rear clip to hold it is place.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser8_zps720951a2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser8_zps720951a2.jpg.html)

Here is the view from the back of the car

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser17_zps9c1fda6b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser17_zps9c1fda6b.jpg.html)


Now, I knew that the diffuser would still be a bit wobbly as it is still just secured to fibreglass and nothing solid, so I wanted to secure it more to the MR2 body work further forward. I have seen that others in the past have done this so I thought I’d do the same.

Looking around the bodywork, I always try to use holes/fixing points that are already there/original. I noticed that on each side of the car were these holes with welded nuts/threads on the inside. (Yellow arrow below) Perfect I thought. No idea what that were used for before. Maybe MR2 arch liners as the passenger one still had a bolt in and what looks like a torn triangular piece of black plastic once I undid the bolt.  However on the passenger side was this support for the MR2 exhaust (yellow circle) which would foul the bracket so I decided to just cut this off. (Driver’s side didn’t have this)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser10_zpsdad4eb31.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser10_zpsdad4eb31.jpg.html)

Removed

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser11_zps6d89baad.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser11_zps6d89baad.jpg.html)

Well as I was in bracket mode today (for those of you who care, this metal was from Tool Station – they are used for window sills/boards I believe LOL) I knocked up this one.  The right-angle bend is already there on this metal when you buy it.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser13_zpsb7c8c4d6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser13_zpsb7c8c4d6.jpg.html)

Bracket installed. Bolted using original MR2 nut (yellow arrow), and then I attached this to the bolt I had made to support the diffuser in the first place (red arrow). The beauty of this is both the diffuser and the rear clip/return are secured to the original MR2 bodywork and via one fixing so no extra holes to drill in the diffuser. It is now rock solid. Very pleased with how it turned out.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser14_zps5aec31f9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser14_zps5aec31f9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser15_zps30d6519e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser15_zps30d6519e.jpg.html)

Other side done

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser16_zps45bba2b3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser16_zps45bba2b3.jpg.html)

Finally I had to fill in a bit of the lip of the diffuser as I wasn’t happy with how it met the car, and then I played around with a rubber trim (Idea nicked from the very-well-read publication, “Beemaman’s 101 greatest tips for a DNA 430 build”). Will do some further work on it later. ***Beems? How far did you rubber seal go down the lip of the diffuser?, Cheers

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104RearDiffuser18_zpsdfb438ec.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104RearDiffuser18_zpsdfb438ec.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 04, 2014, 09:35:56 PM
Added the wipers next that have the jet’s built into the blade part. You need something like this as the MR2 jets were built into the bonnet and therefore are no longer there

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104Wipers1_zpsf00f4d84.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104Wipers1_zpsf00f4d84.jpg.html)


Green arrow is where the tube will connect to and the yellow arrow is where the water comes out

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104Wipers2_zps69c2388c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104Wipers2_zps69c2388c.jpg.html)

This is the plan for the washer –jet set up: In the diagram below the white bottle at the bottom is my new washer bottle with pump. Connected to this will be an in-line valve with no return, a pipe and then a t-piece to split the pipes off and then pipes running up and through and attaching to the wipers themselves. I didn’t have all the pieces so maybe I’ll get to this next week. 

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104Wipers3_zps2b19337f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104Wipers3_zps2b19337f.jpg.html)

Next the plastic that is used to bridge the gap between the frunk area and the DNA front clip. I cut some sections out like this so it could slide right under the other under bonnet plastic cover

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104FrontBonnetSection1_zpsff02a9db.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104FrontBonnetSection1_zpsff02a9db.jpg.html)

The area down to the DNA part is a bit of a slope and the below brackets were getting in the way of that slope. 

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104FrontBonnetSection2_zps0adba3f9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104FrontBonnetSection2_zps0adba3f9.jpg.html)

I removed these and then the black plastic could slope down better towards the clip.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104FrontBonnetSection3_zps81bc1a6d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104FrontBonnetSection3_zps81bc1a6d.jpg.html)

Nothing is bolted down yet, and I still haven’t decided how to fix the plastic at the bottom of the slope. The thing is, you can’t simply drill through at the end edge of the plastic as below this is the front clip large metal bracket that you would have added ages ago that supports the front end. I’m not drilling through thick metal just to secure this piece of plastic. I am thinking about some sort of clip that I can bond and slide the plastic into at the bottom of it. Watch this space.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104FrontBonnetSection4_zpsd6ee63f9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104FrontBonnetSection4_zpsd6ee63f9.jpg.html)


Final job of the day was drilling holes for side indicators. The template on the side of the wings is spot on, but always be cautious with drilling at first and it is a case of trial and error.

Here is the indicator. The connector at the end here you should keep and use in part of the headlight assembly. The high-beam connector plug fits this indicator connector.  I cut it off in the middle.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104Indicators1_zps89aeef8e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104Indicators1_zps89aeef8e.jpg.html)

From inside the wing is the MR2 connector

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104Indicators2_zps4f5b08c1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104Indicators2_zps4f5b08c1.jpg.html)

I plan to extend the MR2 wire slightly and then add a universal connector to this and the indicator to make them removable as opposed to hard wiring the new indicator straight to the MR2 wires.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104Indicators4_zps123a11bf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104Indicators4_zps123a11bf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104Indicators3_zpsf4c50a9c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104Indicators3_zpsf4c50a9c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104Indicators5_zpsc03e8286.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104Indicators5_zpsc03e8286.jpg.html)

Will hopefully do the wiring next week.

That will do for today. Phew!
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on January 04, 2014, 09:59:19 PM
Another great write up Paul! I haven't fitted my rear diffuser yet so like the idea of the extra brackets. What length was the angled bracket you used for this?  :)

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 04, 2014, 10:23:10 PM
I'll measure it next time, but the length would depend on where on the diffuser you fit it. The longer part on mine was over 20cm
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on January 05, 2014, 09:57:38 AM
fantastic info again matey!

One thing on the door speakers, you will need to protect the back of the speaker from water, the nature of cars is such that water will run down the outside of the window and past the seal on the top of the door to get inside. check the original speakers, they have a plastic case round them to protect them.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 05, 2014, 10:00:52 AM
yes you're right, they do have a plastic sort of cover, but this doesn't do all the way around the speaker. i think i'll look into cutting off this part and then bond it to the back of the mdf to mimic what was there before. Another job on to do list.  :D
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on January 08, 2014, 05:41:55 PM
Paul, Your mirror and door seal was collected from me this morning this morning so should be with you over the next few days. Its gone by "Hermes" who aren't the quickest but drop me a PM or text to confirm safe arrival.  :) :)

Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on January 08, 2014, 06:12:35 PM
 ;) nicely done Paul bet it's hard staying motivated in this great british weather but you'll be smiling come summer great build thread thanks it brightens up the winter evenings for me  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 08, 2014, 10:09:17 PM
Paul, Your mirror and door seal was collected from me this morning this morning so should be with you over the next few days. Its gone by "Hermes" who aren't the quickest but drop me a PM or text to confirm safe arrival.  :) :)


Thanks so much Crossy. Really appreciate it.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 09, 2014, 11:00:55 AM
Guys, quick question: The rear deck Ferrari lettering badge (see photo below with the arrow)  - how do most people attach this? I have the badge and it is made of metal and has 2 prong's underneath. I guess on the real cars there are 2 holes in the deck and it fits through and is bonded on the inside of the rear deck. I ask now because if i need to drill 2 holes in the rear deck, i'd rather do it now before it is painted. Also, for the position of the badge, does anyone have the measurements of how far away it is from the bottom of rear deck glass it is? Thanks in advance chaps
Paul

Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on January 09, 2014, 11:10:50 AM
hi paul

i cut off the 2 alloy prongs and rubbed then down flat level with badge and used a strong double sided adhesive tape,takes a bit of time to do but at least it can be removed leaving no holes if you wanted to.and before fitting i slightly bended badge to the correct shape of rear deck before sticking,that way the badge is not fighting to come back into its original shape with the tape holiding it down,
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on January 09, 2014, 03:29:02 PM
On production cars the pins on the back fit into small plastic thimble shaped sleeves which fit into the panel.  This takes up any small difference in dimensions and saves damaging the paint.  Should be available from any OEM distributors.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 09, 2014, 03:38:42 PM
Cheers Wayne for the detailed explanation

Mick, when you say production cars - you mean turn key's built by DNA or real Ferrari's?
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on January 09, 2014, 03:47:24 PM
real ferraris as i think dna wont put them on.but if they did id say stick them lol :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 09, 2014, 03:48:22 PM
doh! yes of course they wouldn't. sorry forget that!!!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on January 09, 2014, 05:35:32 PM
just checked on Eurospares, they are 65p each!!

here is the link http://www.eurospares.co.uk/searchResult_one.asp?S=60324506&TM=1&TMo=375&TA=2&TB=20008 (http://www.eurospares.co.uk/searchResult_one.asp?S=60324506&TM=1&TMo=375&TA=2&TB=20008)

its the top one (part number 60324506), and I know it says its a 360 Challange, but if you click on "Will this fit my car?" its listed as fitting the 430 spider.
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on January 09, 2014, 05:46:11 PM
It would be an older car.  The badge on the boot of my old Mini was held on with them.  More secure than double sided tape. 
I've just remembered that a mate of mine described them as "mouse contraceptives" .  A bit stif for that job but I think you get the idea.
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on January 09, 2014, 10:46:16 PM
Has anyone got the measurements of the correct distance from the back of the glass?  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 10, 2014, 09:24:12 PM
Been doing a few bits at home in the garage so here is a bit of an update.

I have finally finished the build-up of the door cards and I am happy with them. The door card pockets are fully removable as are arm the arm rests so they can be dismantled when they go to the trimmers.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140104DoorCards_zpse2a1dadf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140104DoorCards_zpse2a1dadf.jpg.html)

Also on the steering wheel;  The front plate seems reasonably secure on the wheel (the bit under the airbag cover) as it is wedged in between the spokes, but I wanted it to be more secure.

On the cover are 2 holes marked out slightly. Drill through these and then you can add 2 long bolts that screw into the holes that are on the steering, designed to be used with a steering wheel remover (not that you need one really!) Now the plate is properly secured and the airbag cover can be screwed to the top of it.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140105SteeringWheel1_zpsceff28ec.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140105SteeringWheel1_zpsceff28ec.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140105SteeringWheel2_zps9444876a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140105SteeringWheel2_zps9444876a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140105SteeringWheel3_zps7334ca1e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140105SteeringWheel3_zps7334ca1e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140105SteeringWheel4_zps73eab312.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140105SteeringWheel4_zps73eab312.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140105SteeringWheel5_zps8dff0b12.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140105SteeringWheel5_zps8dff0b12.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140105SteeringWheel6_zps40d3afe3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140105SteeringWheel6_zps40d3afe3.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 10, 2014, 09:36:34 PM
Spent 3 hours on car last night. Did a few jobs that weren't particularly exciting but essential none-the-less

1) Marked out templates for lower grills
2) Did some work on the front arch seem split I had
3) Did strings for dummy engine
4) Came up with a solution to the front engine bay gap cover problem
5) Fitted the passenger arch liner

For the dummy engine strings I used the cord that was part of the rear parcel shelf on the MR2. It has this metal clips installed halfway along the piece to form a loop

I removed them and made the loop at one end of the strings

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140110DummyEngine1_zpse36d3fd4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140110DummyEngine1_zpse36d3fd4.jpg.html)

Next I had already drilled holes for the bolts to hang the string on when I was painting the engine so I added Allen bolts and a nut to make a hanging point

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140110DummyEngine2_zps1bb6b939.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140110DummyEngine2_zps1bb6b939.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140110DummyEngine3_zps244e071f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140110DummyEngine3_zps244e071f.jpg.html)

Then lifted the engine up to support it.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140110DummyEngine4_zpscefd6803.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140110DummyEngine4_zpscefd6803.jpg.html)

Added the string over the outside of the nut and then added another large washer and nut to the Allen bolt to stop it coming off

Tied the other end of the string to this triangle part on the frame. Haven't trimmed off the string as I will wait until I fit the engine for real.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140110DummyEngine5_zps04b57733.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140110DummyEngine5_zps04b57733.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140110DummyEngine6_zps96034373.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140110DummyEngine6_zps96034373.jpg.html)

Because the triangle bit the string is tied to, is further to the front of the car, when the deck is closed the excess strings lies forward and rests on top of the soft top. I.e. it doesn't hang down in the engine bay. With the grill and rain cover installed you won't see the string underneath.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140110DummyEngine7_zpsb5a44403.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140110DummyEngine7_zpsb5a44403.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140110DummyEngine8_zps80602865.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140110DummyEngine8_zps80602865.jpg.html)

With the under bonnet cover I plan to fit butt hinges to the underside part of it. Then I will bond the hinges to the front clip (once back from paint). This way then the piece of plastic can naturally slope down.

If you need to get to the radiator you can just flip it up.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140110FrontCover1_zps8e232438.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140110FrontCover1_zps8e232438.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140110FrontCover2_zps6a2b7943.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140110FrontCover2_zps6a2b7943.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 10, 2014, 09:54:54 PM
So final part of the day was the rear arch liners: I had tried fitting the passenger one before and found it very tight. So I trimmed off the outer edge (edge at the arrow below) by about 0.75 cm all the way along. This gave me just enough wiggle room to get it into the arch without too much stress and sort out the fitting.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140110ArchLiner1_zpsb18a48c0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140110ArchLiner1_zpsb18a48c0.jpg.html)

Once fitted and lined up, you can drill holes for the tabs into the body. Just drill very small holes through the tabs and then the metal body and the tek screw in place. For the holes in the fibre glass body parts, I drilled larger holes and then bolted them. I don’t like screwing directly into the fibre glass as it will eventually weaken. Better to bolt all the way through with washers.

Here it is fitted. Yellow arrows in photos below are tek screws and circles are bolts. When I finally fit these I will have prettier bolts. Probably black, round head Allen screw bolts etc…

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140110ArchLiner2_zps1468fc01.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140110ArchLiner2_zps1468fc01.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140110ArchLiner3_zps601a2705.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140110ArchLiner3_zps601a2705.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140110ArchLiner4_zps4cea660f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140110ArchLiner4_zps4cea660f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140110ArchLiner5_zps5dd4b95d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140110ArchLiner5_zps5dd4b95d.jpg.html)

Now, it will be interesting to see if anyone else had this issue, but for my exhaust I believed it could be fitted only one way. However this means that the pipe come back further and thus would touch the liner. As I was happy with the exhaust set up, I thought it best to cut a hole in the liner so it doesn’t touch and melt the liner. I plan to paint the exhaust black so it will be less obvious, and with the wheel on it will probably be un-noticeable, but I thought I’d highlight it to future buliders.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140110ArchLiner6_zps9ed22a94.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140110ArchLiner6_zps9ed22a94.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on January 10, 2014, 10:25:46 PM
That's still a good write up Paul......even if you have had a few beers!! LOL  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 10, 2014, 10:53:24 PM
That's the beauty of writing it up in Microsoft Word first. There is a spell and grammar check! Hic!  ;)
Title: Re: Paul's 4thirty Build Diary
Post by: cheets on January 11, 2014, 12:24:17 AM
Well Paul is very good yet a gene it is putting my build thread to shame

Cheets  8)
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on January 11, 2014, 07:38:42 AM
Paul
The Furrari had the same problem with the passengers side rear wheel arch, and it did melt.  DNA changed it, for one I think was about 1/2 inch shorter which pulled it clear of the exhaust.  No problem since.  Don't forget this is a kit car not a production car so tolerances build up and have to come out somewhere.
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on January 11, 2014, 02:56:35 PM
 :) good job Paul and a great write up as usual it's shaping up to be an invaluable build thread soon be pulling up at the church in style 8) mate
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 11, 2014, 09:37:16 PM
Cheers for comments/help guys - full day on it tomorrow beckons! yippee! gonna be a chilly one it think!  8)

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 12, 2014, 08:14:03 PM
Total Build Time: 271 hours

Well, I must say it was a bit chilly today! So in between thawing out my fingers this is what I got done:

Planned to check fitment of rear glass. You need to remove the rubber trim bits  (arrows) from underneath the glass first as these are not needed to fit the glass. Keep them for use elsewhere on the car.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112RearDeckGlass1_zpsd53937f8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112RearDeckGlass1_zpsd53937f8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112RearDeckGlass2_zpsc829afe1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112RearDeckGlass2_zpsc829afe1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112RearDeckGlass3_zps21ba01a5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112RearDeckGlass3_zps21ba01a5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112RearDeckGlass4_zps15d94a6c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112RearDeckGlass4_zps15d94a6c.jpg.html)

Here is the deck without glass. Getting the glass to fit is a trial and error exercise which I spent a good hour and a half on. Plenty of used sand paper! I'm pretty happy now. It is not uber perfect but the deck is never going to be 100% flat and square so you don't want to force the glass to be in a position that is not natural for it as I guess it could break. Good news is dummy engine well clears the glass now. I reckon got at least 1cm gap between the red engine and the glass

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112RearDeckGlass5_zps1d406353.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112RearDeckGlass5_zps1d406353.jpg.html)

First fit

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112RearDeckGlass6_zpsd67d603e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112RearDeckGlass6_zpsd67d603e.jpg.html)

Work in progress

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112RearDeckGlass7_zps62413491.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112RearDeckGlass7_zps62413491.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112RearDeckGlass8_zpsc3811e39.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112RearDeckGlass8_zpsc3811e39.jpg.html)

Done

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112RearDeckGlass9_zps92117820.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112RearDeckGlass9_zps92117820.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112RearDeckGlass10_zps2580c353.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112RearDeckGlass10_zps2580c353.jpg.html)


Finished off repairing the front arch from many moons ago. Sprayed with underseal as well

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112Arch1_zps54fee809.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112Arch1_zps54fee809.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112Arch2_zps062451c9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112Arch2_zps062451c9.jpg.html)


Next I removed the MR2 engine cover. You can make out the silver writing when you look through the glass at the dummy engine, so planned to just spray it all satin black. It is held on with domed nuts at the yellow arrows. The red arrow it is just plastic trim clips, but both of mine had broken off!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112EngineCover1_zps6c2acf8a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112EngineCover1_zps6c2acf8a.jpg.html)

Removed

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112EngineCover2_zps5464738b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112EngineCover2_zps5464738b.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 12, 2014, 09:37:44 PM
Next worked on the driver’s rear arch liner: Same as before, trimmed a bit of outer edge and then cut hole for exhaust to clear. Plan to reverse the exhaust bracket so nuts are facing inwards. Bolts used where attaching to fibre glass as before.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112ArchLiner1_zps8ed7e5e6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112ArchLiner1_zps8ed7e5e6.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112ArchLiner2_zps0d0ac82a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112ArchLiner2_zps0d0ac82a.jpg.html)

Fitted back the diffuser again using the brackets I had made. Grill made up for diffuser already back at home

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112RearDiffuser_zpse0446d18.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112RearDiffuser_zpse0446d18.jpg.html)

I had also sprayed the diffuser brackets black before I fitted them back to the car. So diffuser is all fitted up ready for the paint shop.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112ArchLiner3_zpsbcb1ea5d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112ArchLiner3_zpsbcb1ea5d.jpg.html)

Also put back the passenger rear arch liner as I want to test the wheels for clearance before I send the car away.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112ArchLiner4_zpsac008cc1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112ArchLiner4_zpsac008cc1.jpg.html)

Next I extended the wires for the side indicators even so slightly, so indicators can just be connected up when ready. Connectors I am using are circled and will go in the direction of the arrow. I have just cable tied them out of the way for now

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112IndicatorWires1_zpsbb2feefa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112IndicatorWires1_zpsbb2feefa.jpg.html)

Here is the driver’s side - arrows point to the extended wire

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112IndicatorWires2_zps84e47e0a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112IndicatorWires2_zps84e47e0a.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 12, 2014, 09:59:00 PM
Windscreen Washer Jets

As the original MR2 washer jets are on the bonnet and that is now history, you need to have some way of washing the screen obviously. I have changed the wipers on the car to ones that have jet’s included.

I managed to get some black tubing off eBay for the jet’s – sadly it was pretty thick stuff even though the internal diameter is only 4mm.  I connected the tube up to the passenger wiper and then searched for a suitable point to feed it through the scuttle cover.  You need to account for slack for a) when the wiper is moving, and b) when you put the wipers up.

I decided on a hole to the right of the wiper nut – the arrow in the picture below. I had originally drilled a hole at the point circled below but this left me with a lot of tube on show. I make these mistakes so you guys don’t have to! LOL.  ;D I will fill that in later when I paint the scuttle cover. The tube is concealed under the wiper arm and held in place with zip ties. I will of course use black ones when I finally fit this all up!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112WasherJets1_zps97fb4fe0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112WasherJets1_zps97fb4fe0.jpg.html)

Here we have both wiper tubes in place.  Yellow arrow for the passenger wiper, red for drivers wiper and green for the drivers wiper coming back into the engine bay area.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112WasherJets2_zps51eb7091.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112WasherJets2_zps51eb7091.jpg.html)

Here is the tube for the driver wiper going under the wing/round the wiper and into the bay. No holes were needed to be drilled for this side.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112WasherJets3_zps8654a754.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112WasherJets3_zps8654a754.jpg.html)

You need a t-connector piece like this:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112WasherJets4_zps0e999045.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112WasherJets4_zps0e999045.jpg.html)

And a one-way valve: The arrow is the end where the water goes in from the pump.  If in doubt just blow through each end to determine the correct end to use!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112WasherJets5_zpsade53b7d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112WasherJets5_zpsade53b7d.jpg.html)

All connected up. T-piece yellow circle, value green circle. I had to drill a hole through the scuttle to feed the pipe. I will smooth the hole down. No need for a grommet as the pipe walls are literally 4mm thick all the way round.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112WasherJets6_zps73005b66.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112WasherJets6_zps73005b66.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112WasherJets7_zps01af1bcd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112WasherJets7_zps01af1bcd.jpg.html)

Tided up for the photo. Used cable trees to support the drivers pipe along the scuttle

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112WasherJets8_zps6b6ac7d8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112WasherJets8_zps6b6ac7d8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112WasherJets9_zpsc68b62d6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112WasherJets9_zpsc68b62d6.jpg.html)

All connected up and it works! Hooray! I have now dismantled it all and removed the scuttle cover which I will tidy up and paint with car is being sprayed.

Finally for the day I had a look at how the front arch liners go. More details next time, but now a ***Question*** for you gurus.

Below I think is the piece that goes at the back of the front bumper – the piece that connects to the thin pointy arch part that runs along the rest of the arch and attaches to the sill. . This is the passenger side and I believe it fits in in the position shown? Am I correct? Also the tab at the bottom, should this be bent forwards (along dotted line) towards the front of the car and the under bumper piece attached to it as well eventually?

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112FrontArchLiner1_zpsb73f97cb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112FrontArchLiner1_zpsb73f97cb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140112FrontArchLiner2_zpse3d909d0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140112FrontArchLiner2_zpse3d909d0.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 18, 2014, 01:44:31 PM
Total Build Time: 277 hours

I worked on front arch liners next. These are in 2 parts.  Below is the 1st part that attaches to the back of the arch. The pointy bit attaches to the bottom of the sill.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner1_zps75802aae.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner1_zps75802aae.jpg.html)

This notch may need enlarging as it goes between the join of the front clip and the front bumper. It will be obvious when you get there.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner2_zps68e33849.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner2_zps68e33849.jpg.html)

It will attach here at the bottom of the sill

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner3_zpsdaeffa60.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner3_zpsdaeffa60.jpg.html)

The liner fits up inside the arch and one the other side fits inside these metal seems that protrudes on the inside of the MR2

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner4_zpsd914e08a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner4_zpsd914e08a.jpg.html)

I drilled a hole in the bottom of the liner and then the sill and then bolted them together. You'll be able to bolt it as you would have cut an access hole on the underside of the sill when you bonded the rear clip many moons ago! 

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner5_zps3fa00a9e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner5_zps3fa00a9e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner6_zpse4441252.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner6_zpse4441252.jpg.html)

Then I tek screwed the liner in a couple of places as well to secure it.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner7_zpse38658cc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner7_zpse38658cc.jpg.html)

The rest of the liner stays by friction

The other piece is a square like piece that fit inside the lip of the front bumper. I heated the tabs up and bent the larger one at the bottom 45 degrees forwards so it faces the front of the car (red arrow). The other tab I bent back 45 degrees (yellow arrow)  so it could be screwed to the body of the MR2. Bend the small tab before you try to fit it as it will never go in othewise!

I bolted the liner also to the bottom of the front bumper as well (yellow circle).

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner8_zps86b8ba26.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner8_zps86b8ba26.jpg.html)

Now you have the 2 liners that could be secured together (arrows).  Where these 2 liners meet, behind them is a thin piece of metal that used to support the MR2 arches. I had previously trimmed back part of these as they would get in the way of the headlight fitting but retained some of it (see previous posts). You can use this metal to support a zip tie and tied both liners and secure to the car at this point. (Yellow circle is previous tab, tek screwed in place)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner10_zps996d83bd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner10_zps996d83bd.jpg.html)

I drilled a hole through both liners and then through the metal directly behind (yellow circle) and then another hole just through the metal slightly (red circle) further in so the zip tie could be looped and secured tightly

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner11_zps65f20f52.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner11_zps65f20f52.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner12_zpsd7c7006b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner12_zpsd7c7006b.jpg.html)

View from looking inside the headlamp hole of the zip tie

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner14_zps2dda2b08.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner14_zps2dda2b08.jpg.html)

So here is the passenger arch all done

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner15_zps6eed75ec.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner15_zps6eed75ec.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner16_zpse7a18ba9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner16_zpse7a18ba9.jpg.html)

When fitting the lower liner and bolting to the bottom of the bumper, instead of having a hole in the liner, I made a cut out instead like below

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner17_zpseae52892.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner17_zpseae52892.jpg.html)

This means in the bumper you can put the bolt, washers and the nut in first and then put the liner in place afterwards between the bumper and washers etc.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner18_zps6e666d79.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner18_zps6e666d79.jpg.html)

As it is so tight in there and you’d be working blind, trying to thread a washer and nut on with the liner in pace would be very difficult. This way all you need it to tighten up which is a bit easier. The washers grip the liner enough to make it secure enough.

More pictures now of driver’s side:

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner20_zps10d10bf3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner20_zps10d10bf3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401ArchLiner21_zps16ea4e57.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401ArchLiner21_zps16ea4e57.jpg.html)

Next I drilled pin holes for the bonnet and rear deck. These pieces get removed from the car when painted. By drilling these holes, pins or nails can be placed in when refitting these parts to ensure they are put back in the same places.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401PinHoles1_zps6fc54cc8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401PinHoles1_zps6fc54cc8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401PinHoles2_zpsf792e70b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401PinHoles2_zpsf792e70b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401PinHoles3_zpsf22ff328.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401PinHoles3_zpsf22ff328.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401PinHoles4_zps0c04fb56.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401PinHoles4_zps0c04fb56.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on January 18, 2014, 02:15:10 PM
hi paul

great work as always buddy :)

just a quick one i do beleive the bottom of the frt liner which attachs to bumper will need to fit alot farther in than flush with bumper as the wheel will not turn.on mine it was a good 8-10 inches in and the part were it joins other shield needs pushing as high up as possible as i had these problems on mine.its very tight

keep u the good work buddy
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 18, 2014, 02:22:46 PM
Thanks Wayne. Do you mean the bolt that I have put at the bottom of the front bumper is not needed as the liner needs to go further towards the front of the car? I was always going to test the clearance anyway, but thanks as I will look into another method to fix it.


Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 18, 2014, 02:28:40 PM
I worked on wing mirrors next. The MR2 motors fit in the mouldings in the 430 mirrors.  Secured at the same fixing points using tek screws. Here you can see the motor wire coming out of base of the mirror.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Mirrors1_zps41be3f20.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Mirrors1_zps41be3f20.jpg.html)

Next I worked out where to drill the hole for the wire. I've done a larger hole to account for the connector that passes through.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Mirrors2_zps56c6dc08.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Mirrors2_zps56c6dc08.jpg.html)

On the inside of the car I had already filled in the gaps on the triangle parts but I needed to feed the wire towards the front of the car and around the end of the door. You can’t just go straight into the car as the wire would catch the window when it comes up. I decided to file out a channel for the wire to sit. These triangle parts get covered anyway with a plate when the mirrors are done so the wire will be hidden eventually.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Mirrors3_zps3d325ee2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Mirrors3_zps3d325ee2.jpg.html)

Wire threaded and connected

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Mirrors5_zpsf3d027aa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Mirrors5_zpsf3d027aa.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Mirrors6_zpsdc9e0cdf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Mirrors6_zpsdc9e0cdf.jpg.html)

Other side done

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Mirrors7_zps5fde1ade.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Mirrors7_zps5fde1ade.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Mirrors8_zps758aa0d1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Mirrors8_zps758aa0d1.jpg.html)

Next was time to put the guide pins to the test! I wanted to work out the size for the rear grill. The only way to do this is with the rear deck off. First I removed the dummy engine and exhaust hole cover. This are not needed now and will be put away until the day they are fitted for the final time 

I removed the gas rams and then undid the main bolts and lifted the entire rear deck forward. To avoid damage I had also removed the roll bar cover as well. Dad was luckily on hand to help shift the rear deck forward. To future builders it is worth sizing the rear grill up before you start to do the rear deck as you won't need to do all the above! LOL.

Here is it removed

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401RearGrill1_zps9e569a56.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401RearGrill1_zps9e569a56.jpg.html)

This is the piece of plastic that fills the hole.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401RearGrill2_zps0f30c8b8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401RearGrill2_zps0f30c8b8.jpg.html)

I found it a little too long so I trimmed each end and then cut out this section to enable it to fit flush in the cut out areas

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401RearGrill3_zps5fd8c520.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401RearGrill3_zps5fd8c520.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401RearGrill4_zps5b833cd7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401RearGrill4_zps5b833cd7.jpg.html)

I will now cut the grill a similar shape and then when painted I will have the plastic and grill bonded in. I may ask if DNA will do this before they put the deck back on once it is painted to save me having to take the deck off again. I'm sure they will as they are such nice chaps! Wink wink. ;)

Then put the deck back using the guide pins. What a great idea. Goes straight back first time perfectly!

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401RearGrill5_zps61442b82.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401RearGrill5_zps61442b82.jpg.html)

I wanted to look into the fitting of the speedo instrument binnacle cover but I need the speedo surround back in. So I put it back to check

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Binnacle1_zpsc431f53c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Binnacle1_zpsc431f53c.jpg.html)

The cover fits really nicely on the natural curve of the MR2 dash. I had planned to bond bolts into underside of the cover  and drill holes in top of dash but access for drill is very limited and I think doubled side tape will work just fine

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Binnacle2_zps216aa28a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Binnacle2_zps216aa28a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Binnacle3_zps0f2e6179.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Binnacle3_zps0f2e6179.jpg.html)

Removed some more internal trim parts as well as speakers and mdf wood. I plan to paint the mdf wood black and also bond to the inside of the speaker hole some sort of canopy to protect the speakers from water. I'm thinking some sort of plastic bowl cut in half and bonded on. Watch this space.  

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140114Misc1_zps156c07a5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140114Misc1_zps156c07a5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140114Misc2_zps83d8657c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140114Misc2_zps83d8657c.jpg.html)

Covered my wiring in plastic bags and tape to protect it from the paint

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140114Misc3_zpsfd9d7069.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140114Misc3_zpsfd9d7069.jpg.html)

Finally I made some templates for the rear deck grills to cut out later and tidied up some body filled parts here and there

***Next I need some help guys***. I started looking at the rain cover/diverter thing that attaches to the rear deck. How does it all fit together/work? I have a photo below of the parts. Could someone please help me possibly saying which part goes into which and what way round? Or if anyone has some photos as well would be most helpful.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140114RainCover_zpsa57151de.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140114RainCover_zpsa57151de.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on January 18, 2014, 02:50:06 PM
hi paul

yes buddy it does need to go alot further,you could use a stainless brkt attached to the shield as a l shaped piece then bolt that to bumper lip.

what i did with my drain channels is i left them on the side of the bench and there still there now lol :)
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on January 18, 2014, 04:47:15 PM
My drain channels are in a drawer somewhere too!!! I just couldn't figure out how they go, I got to the stage of thinking I'd got a duff set that won't fit together properly! LOL . Would be interested to see exactly how they should go though????  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 18, 2014, 05:00:33 PM
Cheers Guys for the thoughts on the drain channels. Might have to take the same advice!  ::) The mesh I have for the grills is very fine and I don't plan to drive the car in the rain much! I will try and see if I can find any pictures of the drain covers on the forum

Wayne, I will try out the front arch liners and knock up a bracket. you know how I like my B&Q brackets!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on January 18, 2014, 05:19:18 PM
lol paul thats why i didnt fit them my car never saw the wet stuff lol :)

heres a pic if any good to you buddy its tsken from underneath not the best pic but may help :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 18, 2014, 05:28:44 PM
Cheers Beems, I'll probably do the same!!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 19, 2014, 09:28:46 PM
More wing mirror work. Extended and wired up the wing mirror motors. (To remove the motors from the actual MR2 mirrors I had to cut the wires. Maybe it was possible to do this without cutting them but as was planning to extend the wires anyway it didn't matter).

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140119Mirrors1_zpsced0abd7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140119Mirrors1_zpsced0abd7.jpg.html)

Then took the original MR2 mirror glass holder and removed the glass from them. Easiest way to do this is break the glass and pick the pieces out

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140119Mirrors2_zps86a54e94.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140119Mirrors2_zps86a54e94.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140119Mirrors3_zps162a298b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140119Mirrors3_zps162a298b.jpg.html)

The black plastic that is left over needs to be trimmed around the edges so it fits in the 430 mirror. Nothing major just as usual a trial and error exercise. Make sure you have the plastic the right way up. The hook bits go at the top of the motor.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140119Mirrors4_zps65df8e27.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140119Mirrors4_zps65df8e27.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140119Mirrors5_zps0c3e0588.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140119Mirrors5_zps0c3e0588.jpg.html)


Next I placed the actual 430 mirror in to see what it looks like. Looking good :)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140119Mirrors6_zps3082abd3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140119Mirrors6_zps3082abd3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140119Mirrors7_zps2fc89c5b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140119Mirrors7_zps2fc89c5b.jpg.html)

Both done

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140119Mirrors8_zpsb69262ab.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140119Mirrors8_zpsb69262ab.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140119Mirrors9_zpsbf75bb8a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140119Mirrors9_zpsbf75bb8a.jpg.html)

Also sprayed the engine cover satin black to hide the Toyota writing as you can see it through the dummy engine.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140119EngineCover_zps2f323d55.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140119EngineCover_zps2f323d55.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on January 19, 2014, 09:40:03 PM
nice work paul just wait til its in paint and you put the glasses in then :) it will look amazing

how long til paint you reckon ??
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 19, 2014, 09:46:55 PM
Mmmmm. Maybe 2 months and then I'll be making the call  ;D. The to do list is getting shorter (gradually)  Still want to trail fit everything first so re-assembling it is as painless as possible once painted.  Realistically the wedding deadline is not going to happen now (end April) but definitely plan to have it done for summer!
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on January 20, 2014, 07:38:20 AM
All looking good Paul! Like the detail (as usual) on the mirror fitting.  :)

Did you definitely need to lengthen the cables or was this because you routed them differently?
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 20, 2014, 08:24:44 AM
I reckon the standard wire length would have reached anyway, but as I have cut the wires to get the motors out of the mirror housing to start with, I thought i may as well add a bit extra just in case, so i can find a nice wire routing path. I used the wire from the broken motor I had as the extra pieces. Thanks again for the new motor Chris..  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on January 20, 2014, 10:28:15 PM
Good to hear the replacement mirror motor is working o.k. Glad to be able to help mate.  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 22, 2014, 10:50:44 PM
Quick update – made some speaker protectors to hopefully shield them somewhat from any water that get inside the door.

For this I used 2 plastic 0.5 litre mixing bowls bought from Robert Dyas! They are the exact diameter of the hole in the door. I toyed with various way to fit them and in the end I bonded them to the MDF wood.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140122Speakers1_zpsf82fa122.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140122Speakers1_zpsf82fa122.jpg.html)

Below are the original MR2 speakers and you can see that they have this grey lip (see arrow) that protects the speaker from things coming down from above. It is this lip I am trying to recreate. I had a look at taking the lip off the original speaker but it seemed too difficult tbh.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140122Speakers3_zps84398c35.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140122Speakers3_zps84398c35.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140122Speakers2_zpsaf5e2cb8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140122Speakers2_zpsaf5e2cb8.jpg.html)

The pictures say a 1000 words:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140122Speakers4_zpsf8af4664.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140122Speakers4_zpsf8af4664.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140122Speakers5_zps85b2f2e7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140122Speakers5_zps85b2f2e7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140122Speakers6_zpsd0ec760c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140122Speakers6_zpsd0ec760c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140122Speakers7_zpsc6e826b2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140122Speakers7_zpsc6e826b2.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140122Speakers8_zps64828272.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140122Speakers8_zps64828272.jpg.html)

Will check the fitment at the weekend and then paint them all black, along with the MDF.
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on January 23, 2014, 08:29:13 AM
Ingenious and cheap way of sorting a potential water problem!
 
Like your style!  :)
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on January 23, 2014, 05:27:26 PM
 :) blue peter badge on its way Paul  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 25, 2014, 09:57:18 PM
Question people...I take it when I get the car painted, the body shop will remove the windscreen while they paint it? Does this mean the seal that was in there before is now un-useable. I hear of people replacing this seal for one that is more Ferrari like. Does anyone have pictures/details of this new seal and how much it costs etc...thanks as always. Crap weather innit?  8)
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on January 26, 2014, 12:41:27 AM
I had my windscreen replaced with the new type seal.
Beemaman sorted it all out for me.
Looks great. Have a look at my build thread.
It does make a big difference and finishes the car off.
Title: Re: Paul's 4thirty Build Diary
Post by: Darren on January 26, 2014, 01:11:47 PM
The window is bonded, there's a gap all around so the painters can mask it up. the new trim is slightly wider giving the illusion of a thinner window pillar.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 26, 2014, 09:02:56 PM
Total Build Time: 285 hours

Hard slog today on the car. Lots of bending down taking wheels on and off. This is what I got done:

Trailed fitted those speaker pods again. Very pleased that they all line up and will protect the backs of the speakers somewhat. Removed again and will now paint them black and put away for later. Arrow shows the back part inside the door

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Speaker1_zps4fec9a74.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Speaker1_zps4fec9a74.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Speaker2_zps59425a68.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Speaker2_zps59425a68.jpg.html)

Fitted back the engine cover after it had been painted.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401EngineCover_zpsca61742e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401EngineCover_zpsca61742e.jpg.html)

Next job was to test clearance on all the arch liners I had previously fitted. Added all 4 wheels back on the car and checked the rears. All good there. Next looked at the front part:

As beemaman noted last week, the bottom of the front part of the liner needs to go forward otherwise the wheel catches it when turning.

Below is how it was when I fitted it previously. Tight in there.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Arch1_zps2cf66697.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Arch1_zps2cf66697.jpg.html)

So I had a play around with the driver’s side first. I trimmed back some of the liner at the top here (see arrow) so that it would fit in more with the contours of the original car and I cable tied it here using this hole already there in the MR2

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Arch2_zpsafe357ee.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Arch2_zpsafe357ee.jpg.html)

I removed the bolt at the bottom of the bumper and pushed the liner forward.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Arch3_zps7b87d6c7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Arch3_zps7b87d6c7.jpg.html)

As for securing the lower part of the liner I had the idea of bolting a mending plate to the flap that is at the bottom of the liner and then bolt the other end to the inside horizontal lip of the bumper

Below we are now looking thru the headlight hole. The plate is hidden from view from the arch as it is behind the liner.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Arch4_zps07c5d7be.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Arch4_zps07c5d7be.jpg.html)

Here is passenger side done as well. Same set up.  Plenty of room for turning in there and the arch liner is nice and solid thanks to the bolts.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Arch5_zpsf2bd050f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Arch5_zpsf2bd050f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Arch6_zpsf97bfa12.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Arch6_zpsf97bfa12.jpg.html)

here are some pictures of the rear arch liner with the wheel on showing the exhaust pipe through the cut out. It is hardly noticeable and the wheel is nowhere near it. When painted black the pipe should be even better

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401RearArch1_zpsc4926640.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401RearArch1_zpsc4926640.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401RearArch2_zpsb50ef929.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401RearArch2_zpsb50ef929.jpg.html)
 
Tested the wing mirror motors and they all work fine. Rest of the day was spent checking the clearance of the arches. I still had some rubbing on full lock on passenger side. Ever so slightly. I banged further but it is on that folded seam and it just won't budge. So had to grind it back a bit. Think it is clear now. Will still need to check again. Took all 4 wheels off again and removed all arch liners

Here is a picture of the car with roof up and my daughters school bear on the bonnet – I wonder what the teachers are gonna make of this project!!??!!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140126Bear_zpscea4fa4d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140126Bear_zpscea4fa4d.jpg.html)


Finally here is a quick video of me driving the car before the heavens opened today. Definitely had a smile on my face! Enjoy!  ;D

Click on picture to play it

(http://i1315.photobucket.com/albums/t597/pjlucas1/th_20140126DNA430After280Hours_zpsf51de3e7.jpg) (http://i1315.photobucket.com/albums/t597/pjlucas1/20140126DNA430After280Hours_zpsf51de3e7.mp4)
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on January 26, 2014, 09:14:33 PM
Looking good. Bet that drive felt good  :)
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on January 26, 2014, 09:42:19 PM
hi paul

nice job buddy bet you cant wait to get it away at paint now :) looks great in gelcoat driving down the road.

when you fit wooden speaker bezels use some foam on back to stop any vibration and also i fitted dynamat sound deading as door membrane keeps the noise down and makes a nice base for trim to fit over.

you still fitting the removable mirror plates ??

great work buddy superb detailed and organised :)
Title: Re: Paul's 4thirty Build Diary
Post by: cheets on January 26, 2014, 11:06:56 PM
Looking good Paul can not what till i am at the same stage :)

Mark
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on January 27, 2014, 09:37:09 AM
What do you think will be the reaction is going to be when she. Gets dropped off at school in this beauty.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 29, 2014, 08:28:30 PM
What do you think will be the reaction is going to be when she. Gets dropped off at school in this beauty.

Haha! Mick, my mates daughter has already booked it for her school prom and that is in 2016!!!
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on January 29, 2014, 08:55:01 PM
 :) very nice Paul got a feeling a lot of young ladies are going to want a ride in that beauty well done all that hard work is really paying off ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 30, 2014, 05:59:32 AM
Just a little update, nothing much done, just getting organised on the headlights

Here are the lenses and housing taped together and holes marked out where I will drill carefully through the lens and then the housing so they can be bolted together. You do not want to bond these together permanetly as you’ll need to be able to take the whole thing apart every now and then to clean them all out. It should also have some sealant in there like Dum Dum tape (see Rudy's thread), and then as an extra step have tape all around the edges as well over it all.

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Headlights1_zps1b5ed280.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Headlights1_zps1b5ed280.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Headlights2_zps40d9d1ef.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Headlights2_zps40d9d1ef.jpg.html)

Next today the plugs for the main headlight bulb arrived today from eBay. These cost under £5 for both. Bargain. The ends are the Superseal ones, but slightly bigger than the ones at the end of the side indicator lights. Don’t try and look on the web for the Superseal connectors on their own. You won’t find the right ones anywhere. You need to search for Halogen headlight wiring or something like that on eBay and then you’ll find them easily

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Headlights3_zps1a2d28a7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Headlights3_zps1a2d28a7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Headlights4_zps5b5c3501.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Headlights4_zps5b5c3501.jpg.html)

So below is what is needed to build up one headlight:
1: Main headlight plug I have just mention above
2: Plug for the main beam connector. Inside the unit is a gate that opens and closes thus blocking the bulb slightly. To put the main beam on the gate is opened, revealing the whole bulb, thus shining a brighter light
3: Side Indicator. These are just the standard MR2 ones. The housing where the bulb is should fit into the headlight surround
4: Resistor. You get this with your kit. You need to wire this into the indicator wires in parallel to slow down the indicator flash. This resistor gets very hot, so you need to mount it somewhere metal. Most actually mount it on the headlight mounting bracket as it is metal, thus helping it to keep cool
5: LED strips. These are wired into the side light connectors of the original MR2

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Headlights5_zps2a97a0f9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Headlights5_zps2a97a0f9.jpg.html)

Bear with me as I haven’t done any of the wiring yet, but I think the above is correct. If it isn’t you’ll be the first to know
Title: Re: Paul's 4thirty Build Diary
Post by: cheets on January 30, 2014, 09:01:48 AM
Looking good paul i was thing ing of doing the ZENON CONVERSION as it seems to have the all the wiring in it :)
Title: Re: Paul's 4thirty Build Diary
Post by: NYAL F430 on January 30, 2014, 09:06:01 AM
Hi, paul another great write up buddy very helpful, I will be following your headlight progress when I get my headlight lamps back from sha's.  looking forward to your updates

Regards nyal
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on January 30, 2014, 12:01:12 PM
I too am looking at Xenons, but, after investigation, the UK law has 2 rules with Xenon lights:

1. Xenons should have "self leveling" fitted, and
2. headlight washers should be fitted

In the current MOT, I think I read that it states, "if fitted, the self levelling for Xenon headlights should be working correctly" so you can get away with number 1 if you dont have self levelling fitted!

As for number 2, well I dont think its in the MOT, but the police could have you if you dont have them.....

Needless to say, its a grey area in the law at the moment.
Title: Re: Paul's 4thirty Build Diary
Post by: cheets on January 30, 2014, 05:29:45 PM
Thanks for that Phil i will have to have a looking it a bit more then :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on January 30, 2014, 10:58:20 PM
Thought about the Xenon but tbh I am going with what comes in the kit for now. If I want to change I can do set a later date. Don't plan to drive it in the dark much as people can't see it as we'll. lol.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 01, 2014, 10:32:44 PM
Time for a little update: Sadly there is to be no work directly on the car this weekend  :( but still got some little jobs done.
Cut out the rear grill using the black plastic that I measured up and cut previously as a template. Also placed my little horse on the back to see what it would look like.  The horse has 2 small bolts at the back. 

****Do people bolt this still as with the black plastic behind the grill I see little room for the bolts/nut on the other side between the grill and the plastic. Or do people bond the horse on?
 
(http://i1315.photobucket.com/albums/t597/pjlucas1/20140201RearGrill1_zps8e9a2b2a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140201RearGrill1_zps8e9a2b2a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140201RearGrill2_zpsaa22f0db.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140201RearGrill2_zpsaa22f0db.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140201RearGrill3_zps2778270b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140201RearGrill3_zps2778270b.jpg.html)

Next I did some headlight prep. I plan to sort out the wiring for the headlights next week, so thought I’d also get the bracket set up ready as well so at least the whole unit can be bolted to the car in the way it is meant to be when I test all the wiring.

Here are the 2 main brackets that hold the Hella light unit

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140201Headlights1_zpsce1af319.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140201Headlights1_zpsce1af319.jpg.html)

Here is the Hella light unit. You will need to unscrew all 4 silver screw bolts and flip them round (you only need 3 here though for the Ferrari lights)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140201Headlights2_zps9edb31aa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140201Headlights2_zps9edb31aa.jpg.html)

Your kit will also have these 3 plastic washer/grommet type things. These fit into the 3 holes on the L-Shaped brackets

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140201Headlights3_zps51a9b411.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140201Headlights3_zps51a9b411.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140201Headlights4_zps6df93992.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140201Headlights4_zps6df93992.jpg.html)

Add the screw bolts. These can be a bit awkward. Best way is to have the bracket on your lap and then hold the plastic grommet with one hand and then screw the bolt in with the other.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140201Headlights5_zpsa2d7e237.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140201Headlights5_zpsa2d7e237.jpg.html)

Then the light unit can be mounted

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140201Headlights6_zps5651feb2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140201Headlights6_zps5651feb2.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140201Headlights7_zps24da9128.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140201Headlights7_zps24da9128.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140201Headlights8_zps2a584126.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140201Headlights8_zps2a584126.jpg.html)

Then add the other bracket to the bottom

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140201Headlights9_zpscf912cd7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140201Headlights9_zpscf912cd7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140201Headlights10_zpsf7134bfb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140201Headlights10_zpsf7134bfb.jpg.html)

Below are the pieces all prepped.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140201Headlights11_zps4673ef45.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140201Headlights11_zps4673ef45.jpg.html)

The bracket/bolts at the arrow fit to another bracket that is in the below picture which is then bolted to the headlamp carriers that were installed on the car in the early days. With all these brackets you have loads of adjustment available to get the light position just right (hopefully)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025Brackets_zps69c007b1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025Brackets_zps69c007b1.jpg.html)

Holes are here below where the whole thing is mounted on

(http://i1315.photobucket.com/albums/t597/pjlucas1/20131025FrontBrackets9_zpsb09ede70.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20131025FrontBrackets9_zpsb09ede70.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: tbag on February 02, 2014, 09:55:42 AM
hi paul, we normally just bond that horse on because we use the larger square mesh there so the nuts are useless, are you using that mesh as a personal choice because you was given just anuf  of that smaller stuff to do the grills in the engine lid and the rear defusser...
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 02, 2014, 10:19:11 AM
Thanks Tony, yeah i am using that mesh as i prefer it, and it also already powder coated black. The larger squared mesh i find very hard to cut plus i have this other stuff left over from when i was doing my dummy engine. swings and roundabouts really.  I will also use this on the engine lid as well and the rear dissuer and the door speaker grills so it all matches. The holes are very fine on this mesh and the bolts on the horse are too big for it.. I will bond it like you do. got a favour to ask though, when i bring my car to dna to paint, any chance you could fit the black plastic and mesh into the rear section while the rear deck is off? saves me having to take the rear deck off when i get the car back... cheers
Title: Re: Paul's 4thirty Build Diary
Post by: tbag on February 02, 2014, 10:23:35 AM
yh no problem, great build thou, brilliant write ups aswel its like an instruction manual lol,
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 02, 2014, 10:23:02 PM
More headlight work today: This afternoon I drilled out the holes in the lenses and the headlight surrounds for the bolts.

Apart from getting married, drilling the lens has to be one of the most terrifying things I’ve done. Visions of slipping drills and scratching lenses filled my head with dread!!! Thankfully all was ok! Phew!

Best way to do this is mark up where you want to drill the holes in the lens (see my previous posts) ensuring it lines up with the surround part, have tape on the lens where you want to drill and mark the holes. Then separate the lens from the surround again and drill out the holes on the lens. Use a black and decker work bench and place the area where you want to drill only on the bench and drill carefully through the lens (and inevitably, part of the workbench as well! LOL!) Work your way around the lens, drilling the holes, each time only placing the part of the lens you want to drill on the bench and holding the other part with your free hand. This way to can get the lens as flat as possible through the bit you are drilling through, thus reducing chance of slippage

Holes below. I am using M4 screw bolts, so I have drilled M5 holes to allow for some adjustment

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140202Headlights1_zpsf5fb66c6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140202Headlights1_zpsf5fb66c6.jpg.html)

Next, place the lens back onto the surround and then mark through the holes you have just drilled, where you need to drill through in the surround. Remove lens and drill through the surround in much the same way, one at a time, although less terrifyingly!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140202Headlights2_zps6018874c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140202Headlights2_zps6018874c.jpg.html)

So here are all holes drilled:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140202Headlights3_zpsa5a45f20.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140202Headlights3_zpsa5a45f20.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140202Headlights4_zpsc150f8c7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140202Headlights4_zpsc150f8c7.jpg.html)

Trailed fitted the screw bolts with washers and nuts

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140202Headlights5_zps974e3e01.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140202Headlights5_zps974e3e01.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140202Headlights6_zps2fd6080c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140202Headlights6_zps2fd6080c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140202Headlights7_zps01700e77.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140202Headlights7_zps01700e77.jpg.html)

Lenses now removed and packed safely away for reassembly later.

Also finished painting the mdf speaker surrounds

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140202Speakers1_zps1884ff02.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140202Speakers1_zps1884ff02.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 07, 2014, 01:22:28 PM
***NEED HELP GUYS***

I started wiring up my headlights last night and when i got to the side lights, i added in the LED strips. However when the side lights were on, they were very dim, and also only seemed to work when I had the front fog light switch on in the cabin. Thing is i have cut off the connectors for the fog lights as i didn't think they would be needed and taped them up. Hwoever it seems the fog and side lights are connected as the fogs only come on when the side lights are on. Dad has checked the fuses under the bonnet as all seem fine... when i conenct the led strip to the battery charger they light up fine, so the led's are not at fault. should the fog light connectors still be attached to the wires? should this matter? it's driving me mad
Title: Re: Paul's 4thirty Build Diary
Post by: Hendrix on February 07, 2014, 03:11:35 PM
Great thread and build Paul. Are you going to have the chrome look as in the pic around the bulbs mate?
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on February 07, 2014, 03:33:20 PM
It's just a coincidence but I was talking to Roland about this on Thursday.  The New Furrari will be having this done.
There is a company called chromespray.co.uk who can do this.  Not used them yet so I don't know how good they are.

Mick
Title: Re: Paul's 4thirty Build Diary
Post by: tenpin on February 07, 2014, 06:37:05 PM
Re: Sidelights
It's a legal requirement to have (at least) the sidelights on before you can turn the foglights on - so the car is wired that way. You shouldn't need to have the foglights connected to get the sidelights to work.
I suggest you plug the positive of the LED strips into the sidelight connector and connect the other end to some bare metal - that should help determine if it's a power or earthing problem.

 - tenpin
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on February 07, 2014, 08:47:05 PM
I just left the fog light wires and plug disconnected and simply taped them up.
Connected the LED strip lights to the side bulb wires and all was fine.
Hope this helps mate.
Great work on the build.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 07, 2014, 11:09:42 PM
Thanks for getting back guys. I think mine is just poor connection issues on the wiring as I am sure I have all the wires correct. Gonna have another go on it tomorrow in the daylight  - full update on Sunday I hope.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 08, 2014, 04:06:49 PM
Panic over. All lights working as they should now. Problems were some blown fuses and bad connections. Full write up with all wiring details tomorrow.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 08, 2014, 04:08:46 PM
Great thread and build Paul. Are you going to have the chrome look as in the pic around the bulbs mate?
Hi Hendrix, I'm going to paint them silver, not chrome. Thanks for comments, Paul
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on February 08, 2014, 05:23:56 PM
Panic over. All lights working as they should now. Problems were some blown fuses and bad connections. Full write up with all wiring details tomorrow.

Glad you got them all working now Paul!  :)  Looking forward to seeing much needed write up on this topic!
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on February 08, 2014, 06:37:41 PM
Well done mate. :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 09, 2014, 04:14:39 PM
Total Build Time: 293 Hours

Spent Thursday evening and Saturday morning on the car – here’s what I got up to:

I noticed last week when the car was out and it started to rain that water was collecting in the rear bumper near the arch. While in reality when the car is done, water will probably not get through there as much, I thought it be a good idea to drill a drain hole. I tipped some water in there and found the lower point and drilled it each side.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209RearDrainHole_zps371ad1cc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209RearDrainHole_zps371ad1cc.jpg.html)

I also painted the exhaust pipes black in high temperature paint as they show through the cut out I had to make in the rear arch liner. They should be hardly noticeable now when the wheel is back on

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209ExhaustBlack_zps100308ca.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209ExhaustBlack_zps100308ca.jpg.html)

Also painted the sill brackets I had made as well

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209SillBrackets_zps0a577212.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209SillBrackets_zps0a577212.jpg.html)

Next I replaced the Allen bolts I had in the rear diffuser for other normal ones as I wasn’t happy with the countersunk ones I had used previously.  Then I continued to get the car ready for paint. I replaced all the wires on the rear deck catches with temporary wire, removed the alarm trigger and 3rd brake-light flasher unit boxes into the engine bay to enable the body to be painted. Then I removed the front bumper in preparation for the wiring for the headlights…
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 09, 2014, 04:26:16 PM
Rain Channels on Rear Deck


I know we discussed here previously about the rain channels and how most members don’t bother with them, but I stumbled across a picture on Manta’s build diary and saw how he fitted them, so I thought I’d have a quick look again. The below pictures show what I did and how they slide into place. They will need bonding to the frame I think for the final fit, but I am going to play this one by ear. I can’t see how they can divert much rain anyway to be honest, but at least I’ve had a look into them.

Holes drilled here and secured together

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209RainCover1_zps948521bf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209RainCover1_zps948521bf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209RainCover2_zps807f8bca.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209RainCover2_zps807f8bca.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209RainCover3_zps6a66473c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209RainCover3_zps6a66473c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209RainCover4_zpse65bd16e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209RainCover4_zpse65bd16e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209RainCover5_zps812a1ed3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209RainCover5_zps812a1ed3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209RainCover6_zps8db7b69b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209RainCover6_zps8db7b69b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209RainCover7_zps705a500a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209RainCover7_zps705a500a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209RainCover8_zps7b0c934d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209RainCover8_zps7b0c934d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209RainCover9_zps1706f209.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209RainCover9_zps1706f209.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209RainCover10_zps74676226.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209RainCover10_zps74676226.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209RainCover11_zps37d75ce4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209RainCover11_zps37d75ce4.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209RainCover12_zps16f49fcf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209RainCover12_zps16f49fcf.jpg.html)

I’ll give the pieces a quick paint of satin black while the car is away and see how it fits once I have the grills in there before deciding whether to fit them permanently
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 09, 2014, 05:21:15 PM
So on to the main event, headlight wiring: Big thanks to all, especially Crossy who helped me a lot over the past few days with advice and pictures from his MR2 of connectors etc…This task isn’t particularly difficult but preparation and good solid connections are key.  I hope this guide helps many future builders and if anyone thinks things aren’t quite right, please let me know and I can make corrections where needed. Enjoy!


430 / 4Thirty Front Headlight Wiring Guide

Introduction

The below guide should help you wire up your front headlights and indicators for your 430. Please note this guide is for the 2003 onwards MR2 – the Facelift model. One of the differences is that the newer MR2’s have different headlights.  Many MR2 owners upgrade their headlights to the face-lift versions. The main difference is that on the older cars the headlight and beam functioned on just one bulb. The facelift lights have 2 separate bulbs for this.  Please note, the MR2 owner’s manual that Phil has posted in the owners section on this forum is for the older cars, so the headlight wiring diagrams there are not valid for facelift cars. This guide should be all you need for the headlights.

Just for clarity in this guide, when I say the below I mean….

•   Headlight: this is the headlight used for normal driving in the dark
•   Beam: this is when you put your beams on, when flashing someone/wanting more light when there is no oncoming traffic

MR2 connectors – below are the MR2 factory connections to help you identify what is what and label accordingly before you start:

MR2 Headlight:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209HeadlightMR2_zps10df4795.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209HeadlightMR2_zps10df4795.jpg.html)

MR2 Beam:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209BeamMR2_zps7cea7f56.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209BeamMR2_zps7cea7f56.jpg.html)

MR2 Side Lights:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209SideLightMR2_zpsf7d5f50c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209SideLightMR2_zpsf7d5f50c.jpg.html)

MR2 Front Indicators:

No picture, but there are pictures further in the guide. You use the same connectors as the MR2 and the bulb and holder fits into the 430 headlight surround with a little bit of adjustment to the surround. It is a twist and lock type connection into the surround.  The actual Bulb holder is unique as it is a bayonet type bulb that fits into it. The wires will need extending though.

Fuses:

There are 3 fuse boxes on the MR2.
A)   One under bonnet on passenger side
B)   One just inside the door on passenger side below the A-pillar (outside of glove-box)
C)   One in the rear next to the battery.

Most of the fuses you need are the mini-blade type. I suggest you have a selection before you start just in case.

The headlight/beam fuses are located in fuse box C, in the most awkward place (typical) – see below

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209Fuses1_zps8e5c8497.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209Fuses1_zps8e5c8497.jpg.html)

 The sidelights/fog lights et al, are in the fuse box B. On the cover there is labelling showing exactly what is what:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209Fuses2_zpsa897d3c5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209Fuses2_zpsa897d3c5.jpg.html)

As you go along, obviously you want to test what is what as you cut wires and check that, for example, when you think you’ve switched on the headlights, there is power to that wire etc.., so you’ll need a good circuit tester. I found that the metal on the MR2 is not the best for a good earth. So I recommend, taking your basic circuit test and extending the wiring so that you can bolt it straight to the negative on the battery like I have done below. Then you know you’ll always have a good earth for testing wires. It will drive you mad otherwise. Below arrow shows the circuit tester bolted to battery

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209EarthLead_zps7ffbe3a8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209EarthLead_zps7ffbe3a8.jpg.html)

One word on the fog lights: The wires for these will be grouped/covered together with the side indicator ones. On the passenger side these run down the wire to the horn and the connections are there. On the driver side, they just run down on their own. In the early days I had just cut off my fog wires and taped up as I wasn’t going to use them. No reason why you cannot leave the connectors there and just secure and tape them up either.

Here are all the MR2 connectors I have just spoken about all labelled up

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209MR2WiresLabelled_zpsdba311f6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209MR2WiresLabelled_zpsdba311f6.jpg.html)


Just a refresher on a photo I posted previously about the whole 430 headlight setup:

(http://i1315.photobucket.com/albums/t597/pjlucas1/201401Headlights5_zps2a97a0f9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/201401Headlights5_zps2a97a0f9.jpg.html)

1)   Headlight connector – buy this connector off eBay. It is a larger Superseal type one - see previous post for details. Wires should be red and black. The wires will be extended naturally but using the new eBay connector and wire
2)   Beam connector – this connector is cut off from the side indicator for the 430. This is a Superseal type. Wires should be white and black.  MR2 wire doesn’t need too much extending. 15cm or so
3)   Indicators – normal MR2 ones. You will just need to extend the wires as they won’t reach the 430 headlight surround, and also add the resistor in to slow down the indicator flash
4)   Resistor  - as noted in 3 above
5)   LED strip lights. Wire these up to the side light connectors. +ve and –ve need to be the right way round. I plan to have a long wire from the LED lights so no need to extend the MR2 wiring harness.

On the 430 Hella light unit the headlight/beam is just one bulb, not 2 separate ones. The way it works is the bulb is always on and powered by the headlight connection, BUT inside the unit it a gate. By default this gate is closed, thus restricting the light that shines out by the bulb. When you turn on the beam, the gate mechanically opens, thus shining more light thru giving the beam effect.

 So here are the most important parts – wiring colours

Drivers Side:

Headlight
•   MR2 Red with Blue stripe …connects to… Red on Superseal connector
•   MR2 White with Black stripe …connects to… Black on Superseal connector
Beam
•   MR2 THICK Red with Blue stripe …connects to… White on Superseal connector
•   MR2 Red with Yellow stripe …connects to… Black on Superseal connector
Side Lights
•   MR2 Green is POSITIVE
•   MR2 White with Black stripe is NEGATIVE
Indicators
•   MR2 Green is POSITIVE
•   MR2 White with Black stripe is NEGATIVE

Passenger Side:

Headlight
•   MR2 Red …connects to… Red on Superseal connector
•   MR2 White with Black stripe …connects to… Black on Superseal connector
Beam
•   MR2 THICK Red …connects to…White on Superseal connector
•   MR2 Red with Yellow stripe …connects to… Black on Superseal connector
Side Lights
•   MR2 Green is POSITIVE
•   MR2 White with Black stripe is NEGATIVE
Indicators
•   MR2 Green is POSITIVE
•   MR2 White with Black stripe is NEGATIVE

In terms of actually doing this wiring I strongly recommend a) you do this before the car is painted as it can be fiddly and you don’t want to worry about scratching fresh paintwork and b) you have removed the front bumper. I found I did most of the work through the actual headlight hole as this is where the wire ends basically sit. Take one side at a time, test with the circuit tester as you go along and ensure you don’t touch bare wires together as if you do fuses can get blown. Also would advise doing this in daylight if possible as it is easier.

The following is some photos of the wires/connectors as I went along as well as how to wire in the resistor into the indicators

 (http://i1315.photobucket.com/albums/t597/pjlucas1/20140209Beam430_zpsb45d241c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209Beam430_zpsb45d241c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209SideLight430_zpsd4674b70.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209SideLight430_zpsd4674b70.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209Headlight430_zps9d4587b6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209Headlight430_zps9d4587b6.jpg.html)

Indicator Resistor:

Here is the resistor. It needs to be mounted on metal as this is like a bulb and get very hot. Most people mount it on the headlight metal carrier.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209IndicatorWiring1_zpsf373215d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209IndicatorWiring1_zpsf373215d.jpg.html)

I drilled 2 holes here, from the other side and then bolted using tiny screw bolts. I had to enlarge slightly the mounting holes in the resistor

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209IndicatorWiring2_zpsbbc8b3db.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209IndicatorWiring2_zpsbbc8b3db.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209IndicatorWiring3_zps56db767b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209IndicatorWiring3_zps56db767b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209IndicatorWiring4_zps7fbdfe0e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209IndicatorWiring4_zps7fbdfe0e.jpg.html)

I used electrical connectors to connect in parallel, the resistor wires

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209IndicatorWiring5_zpsd1019d0c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209IndicatorWiring5_zpsd1019d0c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209IndicatorWiring6_zps7aa7fc64.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209IndicatorWiring6_zps7aa7fc64.jpg.html)

Then I wrapped up all wires in amalgamation tape to protect them all and make it all look neat and tidy

All wired up

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209430WiringFinal_zpsc7c29724.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209430WiringFinal_zpsc7c29724.jpg.html)


Next I started the fit up of headlights – I trail fitted with the headlamp surround but found I needed to cut the corner of the headlamp unit. This is a very common thing needed and will help with light adjustment later on. When cutting here, make sure the headlight is covered/taped up to protect it from scratches etc...

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140209HeadlightCornerCut1_zps1d8557b5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140209HeadlightCornerCut1_zps1d8557b5.jpg.html)

Then I ran out of time. Here is a short video of the lights all working on driver’s side. Click on image to play

(http://i1315.photobucket.com/albums/t597/pjlucas1/th_20140209HeadlightVideo_zpsac7170c4.jpg) (http://i1315.photobucket.com/albums/t597/pjlucas1/20140209HeadlightVideo_zpsac7170c4.mp4)

Hope this helps all  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on February 09, 2014, 07:06:15 PM
Excellent and as expected detailed write up Paul! This will help many future builders. Just one small thing to add is that the voltage droppers for the indicators can be fitted either at the front of the car or the rear if you prefer.

Loved the write up and video as well you flash git! LOl !! :)
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on February 09, 2014, 07:47:19 PM
 :) great work as always Paul your really getting stuck in this is an amazingly detailed build thread well done mate  ;)
Title: Re: Paul's 4thirty Build Diary
Post by: sundog on February 09, 2014, 08:31:39 PM
Imo its the most detailed build yet. Every picture has a description like the bible with it . Good mate!! :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 10, 2014, 12:17:19 PM
Cheers for all the comments and encouragement guys. It really helps. Plus I am enjoying doing the diary almost as much as the build itself. It certainly beats being forced to watch Dancing on Ice with my better half! LOL.  ;D. I also plan to make a slide show of a lot of the photos that I have taken over the build so people can visually watch it take shape! They'll be a few parts to that as well I reckon!
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on February 10, 2014, 10:45:44 PM
 ;D haha I know where your coming from with the dancing on ice lol all I can say is thank god for people like yourself  this forum and my iPad  ;) keep up the great work and the slide show sounds great
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on February 10, 2014, 10:50:34 PM
Paul,
I agree with what everybody has already said. Your build tread is a credit to you and will be invaluable to fellow builders. It's the best by far. I think it should be a build reference as the detail is fantastic.
Great work on the car and cannot wait to see it painted and at the shows. Credit it you.
Rudy
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 12, 2014, 10:18:56 AM
Looking good. Bet that drive felt good  :)

Certainly did - here's the proof

Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on February 12, 2014, 01:20:13 PM
The smile says all the hard work is worthwhile 8)
keep up the great work, soon be there
Dr. MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: cheets on February 12, 2014, 08:37:17 PM
looking good Paul still got mien on axle stands lol bin plying a bit more with the rear diffuser and door cards will post some pics later :)

Mark
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 13, 2014, 08:59:24 PM
Evening all. I had 4 hours on the car today (a wedding anniversary treat to myself) so this is what I got up to:

Added brackets to the rear lights to make them more secure. I did mine slightly different to Cheets as I used a single bracket per bolt. I had planned to only do 1 extra per light but will do 2 in total per light so there can be no doubt. I used a metal strap and bent accordingly to form the brackets

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213RearLights1_zpsab872d48.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213RearLights1_zpsab872d48.jpg.html)

I bonded mine with Stikaflex

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213RearLights2_zps15fd77b2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213RearLights2_zps15fd77b2.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213RearLights3_zps188d6682.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213RearLights3_zps188d6682.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213RearLights4_zps93ef8ec9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213RearLights4_zps93ef8ec9.jpg.html)

Still need to do the 2nd bracket on the outer lights but I had run out of metalwork. I have another strip at home so will finish off on Saturday.


Fuse boxes

When I was doing the rear lights and the fuses blew, I found that to take the lid off the rear fuse box was a right pain as you are restricted somewhat by the rear clip (see arrow). It is ok if the battery is removed but you don't want to do that each time to check a fuse!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213FuseBox1_zps7286b529.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213FuseBox1_zps7286b529.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213FuseBox2_zps67dae0c6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213FuseBox2_zps67dae0c6.jpg.html)

So thought it would be a good idea to file out a slight channel to give me just enough room to get the lid on and off a bit easier

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213FuseBox3_zps4c57164f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213FuseBox3_zps4c57164f.jpg.html)

Also on the front fuse box. With the lid off you'll see that the bottom left corner actually sneaks below the edge of the inside of the wing (arrow). This means the fuse box lid cannot go on as it is as the wing is in the way.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213FuseBox4_zpsee27ab71.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213FuseBox4_zpsee27ab71.jpg.html)

I originally had the idea to cut the corner off the fuse box and fill in edge so it would avoid the wing. However this still leaves the bottom of the fuse box exposed. Given where the fuse box is there is real risk that water will get into it between the wing and the bonnet.  So I thought about cutting away part of the return lip on the wing so the cover can fit without fouling.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213FuseBox5_zps8e7e9667.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213FuseBox5_zps8e7e9667.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213FuseBox6_zpsb52149e4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213FuseBox6_zpsb52149e4.jpg.html)

I've already cut the lid but a quick text to Crossy and a new lid is in the post to me! (Cheers matey - I'll be buying you a whole pub-full of beers at this rate!)

So you can see below that if my fuse box lid was as untouched it would now clear the wing and protect all fuses as it should

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213FuseBox7_zps9ac0ae32.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213FuseBox7_zps9ac0ae32.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213FuseBox8_zps7cfe3f82.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213FuseBox8_zps7cfe3f82.jpg.html)


Here are the rear light brackets from the outside. I will paint them all black on Saturday so they all look nice.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213RearLights5_zpsd6d6bbcc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213RearLights5_zpsd6d6bbcc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213RearLights6_zpsb13d1c4d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213RearLights6_zpsb13d1c4d.jpg.html)


I next started on trimming the b-pillar trim piece so that it fits under the roll bar cover

I found the best way to do this is to remove the roll bar cover and the roll bar cover bracket (only a few bolts/nuts to undo) and then put the trim piece as it normally goes on the MR2 and then put the metal bracket back on to get an idea of where you need to cut away

In the below photo is everything removed and the trim piece already cut along the red line

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213SeatBeltCover1_zps28feac26.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213SeatBeltCover1_zps28feac26.jpg.html)

The circles below are where bolt holes need to be exposed to attached the roll bar cover bracket that goes on top, so it is these areas where you’ll need to trim away

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213SeatBeltCover2_zpsf555bed4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213SeatBeltCover2_zpsf555bed4.jpg.html)


As others have said before it is a massive trial and error exercise and can take a long time to trim it down. I've managed to do the passenger side and I'm pretty happy with it. I may have trimmed a bit too much on the side that goes right next to the glove box door but I'm sure I can make it look ok eventually. It is probably hidden a lot by the seat anyhow.  (or it’s another call to Crossy for another piece LOL)

Trimmed where the yellow line is and later on when the roll bar cover is on, the part with the red line as well

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213SeatBeltCover3_zps01c33db2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213SeatBeltCover3_zps01c33db2.jpg.html)

Arrows show the previous circled areas trimmed to clear the roll bar cover bracket

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213SeatBeltCover4_zps6957fa32.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213SeatBeltCover4_zps6957fa32.jpg.html)

Fitted

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213SeatBeltCover5_zps4cdf38e4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213SeatBeltCover5_zps4cdf38e4.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213SeatBeltCover6_zpsa742cf96.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213SeatBeltCover6_zpsa742cf96.jpg.html)



Then on way home I dropped the seats and door cards at the trimmers. I wanted a tan/beige colour but not as light as cream. One of the colours the trimmer had was called Ferrari beige so it had to be that one! It must be fate.  And it will have Ferrari red double stitching as well.

Seat design wise I am going for the below with silver eye lets and will have the same double stitching as Rudy has on his door cards.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213Seats_zps0e24ac7e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213Seats_zps0e24ac7e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213DoorCards_zps85aad3c6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213DoorCards_zps85aad3c6.jpg.html)


One final thing on headlight brackets: When I was fitting up mine last weekend, once I bolted the headlight unit to the triangular table shaped piece, my lights sat far too high and poked out of the headlight hole. I had a look at these table pieces and it turns out the vertical parts should point down not up. The pieces that I had pointed upwards. The reason why they were pointing up is the bracket bits underneath had been welded incorrectly – on the wrong side. This is obviously nothing major, just one of those things. The kit is has so many pieces and now DNA produce so many different cars, with some components being shared among different models and some unique to each model, these issues are bound to happen every now and then. A quick email to DNA on Monday morning, Roland called me  before lunch, we had a chat, and he understood perfectly what I meant, and 2 pieces were in the post that day and I had them Wednesday. Boom! Great service as usual.  (DNA, please don’t think I am having a go, just want future builders to be aware and hopefully won’t have this issue and save everyone time and money.) I also mentioned this to highlight the great service DNA provide. Below photo shows what I am talking about. Ones on right are the good ones:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140213Brackets_zps75b1d13e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140213Brackets_zps75b1d13e.jpg.html)

More work planned for Saturday morning. Haven’t I got such a great and very understanding wife guys? Love you Jules!!!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: NYAL F430 on February 13, 2014, 10:34:47 PM
Hi, paul great write up as usual, I had also done the headlight bracket thing aswell a few days ago after looking through a couple of build threads, but haven't had time to fix the headlights to it yet, so it's great to know that you have also done the same and that I didn't just break my headlight bracket lol.

Keep it up mate, not far from paint now

Regards nyal
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 15, 2014, 10:14:56 PM
As the time is close for work to start extending my garage to fit the car in, I have (yet again) measured various points of the DNA 430 and noted these down. I thought it would be helpful to share with others, so below is a diagram showing the measurements/dimensions of the DNA 430/4thirty. Hope this helps someone

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140215DNA4THIRTYFINAL_zps4834982a.png) (http://s1315.photobucket.com/user/pjlucas1/media/20140215DNA4THIRTYFINAL_zps4834982a.png.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 15, 2014, 10:23:20 PM
Sadly there is to be no work directly on the car this weekend as my wife is poorly, but I’ve managed to bring the front bumper home to do some work on hopefully on Sunday.  As previously mentioned I’ve been checking the dimensions and boy, this is a wide car.  ;D Here are some pictures showing you.

My garage when extended, the door frame here will be adapted and made wider. The car would fit through currently without the wing mirrors on but not with them on.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7770_zps5840052a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7770_zps5840052a.jpg.html)

Here is the front bumper against some other cars. A C Class Merc and a 5 Series BMW. It is wider than both!  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7766_zps8bca96c8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7766_zps8bca96c8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7767_zps4069f8cb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7767_zps4069f8cb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7768_zpsa89edef4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7768_zpsa89edef4.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7769_zpscf05374c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7769_zpscf05374c.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 15, 2014, 10:24:38 PM
On the front bumper, I need a bit of help. Looking at the front bumper and the scoops/ducts, have I got these the right way round? Looking into how they fit, I think this is the best way they would fit... thanks in advance. Paul

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140215FrontBumper1_zps6c6508f1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140215FrontBumper1_zps6c6508f1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140215FrontBumper2_zps76bf0bf1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140215FrontBumper2_zps76bf0bf1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140215FrontBumper3_zpsee31aba0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140215FrontBumper3_zpsee31aba0.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on February 15, 2014, 11:14:18 PM
Right or wrong, thats how I fit mine ;D
Have you looked at the roller doors for garage? I,ve recently fit some on mine and they fit behind the opening not inbetween, may give you more room by removing the door frame and fitting roller at rear of brickwork
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 16, 2014, 11:28:40 AM
Cheers Dr MADMAN. roller door is not an option. I need to reuse the current door as it only 1 year old and cost £500. It doesn't matter as the garage is being lengthen by building it forward so a new opening has to be built for where the garage door needs to be. I am having the opening built as wide as possible and then adapting the current door to fit the wider hole. Should be simple enough. Just cutting the frame at the top in half, then adding a piece of steel I between to widen frame slightly and then extending one of the doors in the middle. Simples.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on February 16, 2014, 12:28:29 PM
Being my usual helpful self.  Can you just remove a bit of the frame to allow the mirrors to pass through.

Not being able to get out of the 430 with the roof up when it's in the garage is one of my reasons for going to the California.

Don't forget to carpet the wall of the garage to save your paint.  You can even use 1970 swirly stuff if you've got any.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 16, 2014, 09:28:55 PM
Total Build Time: 300 hours

Did some work on the front bumper today: First the front number plate. The 430 bumper is quite curved so I didn’t want to just stick the number plate on. I wanted it bolted. So I thought I’d just use an old plate from Dad’s car as a guide and mark up and cut 2 holes that will be secured with the plastic number plate bolts

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140216FrontNumberPlate1_zps1cb3efa8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140216FrontNumberPlate1_zps1cb3efa8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140216FrontNumberPlate2_zpsc104ccd4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140216FrontNumberPlate2_zpsc104ccd4.jpg.html)

Here you can see just how curved it is:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140216FrontNumberPlate4_zps38cf9c56.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140216FrontNumberPlate4_zps38cf9c56.jpg.html)

Next I looked into the under bumper cover. I wanted to at least see how this when before the bumper was painted. I’m glad I did. I had the lower arch liner pieces as well and I simulated how these were fitted to the side of the bumper and the got the under bumper cover in place. Sorry I don’t have a photo of this, but it will become obvious when you do it. The lower arch liner pieces have a tab on them that you bend 45 degree forwards so you have a shelf for the under bumper cover to rest on.  However you should still secure it around the edge of the bumper. I chose to use small Allen bolts. They probably won’t be visible on the car, but they are nicer looking and normal bolt heads. The below pictures show these fixing points circled

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140216FrontBumperUndercover1_zps35b37c93.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140216FrontBumperUndercover1_zps35b37c93.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140216FrontBumperUndercover2_zps9a6e7c4f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140216FrontBumperUndercover2_zps9a6e7c4f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140216FrontBumperUndercover3_zpsd40e20a3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140216FrontBumperUndercover3_zpsd40e20a3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140216FrontBumperUndercover5_zps216c9b76.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140216FrontBumperUndercover5_zps216c9b76.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140216FrontBumperUndercover6_zps84dfa386.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140216FrontBumperUndercover6_zps84dfa386.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140216FrontBumperUndercover7_zpse19a6ec0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140216FrontBumperUndercover7_zpse19a6ec0.jpg.html)

Make the holes bigger on the under bumper cover than the bolts and use large washers to give yourself some adjustment later on:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140216FrontBumperUndercover8_zpsf02bbd2c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140216FrontBumperUndercover8_zpsf02bbd2c.jpg.html)


Then I got my tinsnips out and cut out some grills. I definitely recommend you wear work gloves as if you don’t you’ll have no skin left on your knuckles

Main Front Bumper Grills:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140216BumperGrill1_zpsea4a9336.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140216BumperGrill1_zpsea4a9336.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140216BumperGrill2_zpsf18c067f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140216BumperGrill2_zpsf18c067f.jpg.html)

Rear Lower Side Vent Grills:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140216SideGrills_zps1518c8e4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140216SideGrills_zps1518c8e4.jpg.html)

Rear Deck Grills:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140216DeckGrills_zpsa7f891a2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140216DeckGrills_zpsa7f891a2.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 16, 2014, 09:32:59 PM
Being my usual helpful self.  Can you just remove a bit of the frame to allow the mirrors to pass through.

Not being able to get out of the 430 with the roof up when it's in the garage is one of my reasons for going to the California.

Don't forget to carpet the wall of the garage to save your paint.  You can even use 1970 swirly stuff if you've got any.

Don't worry Mick, it is going to be like a rubber room in there before the car comes back... no carpet around here at moment. I live in a world of laminate floor! I sure I can get some cheap off cuts from the local carpet right!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 18, 2014, 11:22:36 PM
Well yesterday another mile stone was reached in my build. The car has now been booked in to be painted. Yes I feel I have gone as far as I can but now I need to bite the bullet.   So it goes to DNA for painting on 7th March. They'll still be a fair bit to do when it comes back but hopefully the nasty surprises are out of the way and it will be more a case of just reassembling it all and doing more 'pretty' things. All wiring is done as well suspension. Plenty of things to be sprayed while car is away but that is all part of the plan.

So that means only 2 weekends left to get all the jobs done. Eeek! The list isn't particularly long really and some are not really urgent but still, I will try. Dad is more mobile now so he is now able to help during the week. So fingers crossed I get it all done in time. In case anyone has missed it I am going for the traditional Rosso Red and silver wheels. No stripes etc... Just select parts satin black like on the real car.  Having the ceramic brake discs on the normal 430 calipers. Not sure about caliper colour. Was think gold as red and gold go nicely. We'll see.

Just like to say big thanks to everyone who has helped me get this far. You know who you are.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: cheets on February 19, 2014, 12:09:57 AM
Thats good news and the thanks is coming back to you for the help i have got from you  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on February 19, 2014, 11:45:53 AM
Wow...that must be SO exciting!! imagine...very soon you will have a perfectly shaped and painted car to play with...im so jealous!

I MUST get my act in gear and get mine built!...if only I didnt work away from home 5 days a week and was so busy at the weekends...still, I always knew it would be my background hobby and it will be ready when its ready!

Well done mate.
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on February 19, 2014, 07:07:38 PM
Paul,
That's great news and well done on an excellent build.
Cannot wait to see you and the car at the shows this year.
Great colour choice. As Madman would say, welcome to the Rosso brigade.  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 20, 2014, 10:29:01 AM
Thanks for comment guys

Phil - mate, you've just had a bit of bad luck last year that slowed you down. You'll get there matey and we'll all be there to help you along the way.
Rudy - yep agreed, it can only be 1 colour (I know I'm gonna start a row here now, LOL  ;D)

Done a bit more work last night so will update with some pictures tonight hopefully.
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on February 20, 2014, 12:34:52 PM
Thanks for comment guys

Phil - mate, you've just had a bit of bad luck last year that slowed you down. You'll get there matey and we'll all be there to help you along the way.
Rudy - yep agreed, it can only be 1 colour (I know I'm gonna start a row here now, LOL  ;D)

Done a bit more work last night so will update with some pictures tonight hopefully.

            No rows from me ;D great colour choice, now where have we seen it before? I know on the genine thing ;D
better than yellow or blue, (now thats how you start a row ;D) all in fun :-*
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on February 20, 2014, 01:10:17 PM
If they weren't meant to be yellow why did they name it after the Great Mans home town.  It's not MODENA YELLOW by chance.  :-)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on February 20, 2014, 01:47:45 PM
The new club...Madmans Yorkshire Rosso Posse!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 20, 2014, 01:50:05 PM
so come on then Phil - what colour should a Ferrari be?  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on February 20, 2014, 01:52:51 PM
original ferrari colour is yellow but i think when the race teams changed to red it just stood out more so they stayed with that.

i like yellow but red looks so shiny :) :)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on February 20, 2014, 02:38:48 PM
hey...my previous post meant that I WILL be joining the Madmans Yorkshire Rosso Posse!
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on February 20, 2014, 02:56:13 PM
Beemaman
Yellow is the house colour of Ferrari.  In the old days when the countries cars were painted in country colours (British Racing Green, French Blue, Japan White etc.) the Italians painted theirs red.  When Ferrari formed the Scudari ( Italian for a racing stable) and became the Italian national team they adopted red as their colour.

M
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on February 20, 2014, 05:34:17 PM
The new club...Madmans Yorkshire Rosso Posse!
Rosso Corsa the only way to go ;) ;)
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on February 20, 2014, 05:38:12 PM
so come on then Phil - what colour should a Ferrari be?  ;D
            Hey Paul, have,nt you seen Phils Green machine?
Phill has Red running through his veins, the correct colour, same as the correct colour for Ferrari :-*
MADMAN ;)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 20, 2014, 10:27:31 PM
Well there is certainly one thing we can agree on, and that is we can never agree on the best colour! LOL   8)

Anyway back to business.  I thought I’d share with you how to do the upper rear grills on the car. These are quite involved so big thanks to Beemaman on his tips on what to do. A while ago I made template for the holes and worked out how the grill squares/diamonds would need to go when on the car. I drew these on the templates.

I stuck these templates on card again and then cut around approx. 3cm extra card to increase the size of the template. You want to cut a larger grill than you need to help bond it into place plus the wire mesh used is very thick and hard to cut. You need to use an angle grinder, so you want plenty of area between the rough cuts and the edge of the wire mesh that will be seen.  I wasted £20 buying various hand wire cutters. Still I now have those tools for life!! LOL

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220Grills1_zps204f1460.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220Grills1_zps204f1460.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220Grills2_zps2fbce7de.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220Grills2_zps2fbce7de.jpg.html)


Tape the template to the underside of the wire mesh

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220Grills3_zpsa58c0a77.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220Grills3_zpsa58c0a77.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220Grills4_zps4f5146dc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220Grills4_zps4f5146dc.jpg.html)


Then turn over the wire and spray primer around the edge to mark out the template on the wire mesh. Then you have the perfect lines to cut the shape out with the angle grinder

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220Grills5_zps54f1bfcf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220Grills5_zps54f1bfcf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220Grills6_zpsa149d587.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220Grills6_zpsa149d587.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220Grills7_zps586dd0cc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220Grills7_zps586dd0cc.jpg.html)


Done. Chances are they may be a bit big, but you can always trim back excess before final fitting

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220Grills8_zps6f6364c2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220Grills8_zps6f6364c2.jpg.html)


Next, I cut the corner of the other headlight. Here’s a tip: it is a lot easier to cut these if they are bolted to the L-shaped mounting bracket. If you do this and then rest it on a Black & Decker workmate, chances are there are some holes in the workmate where the bolt sink into to help it become steady. See arrows below. I cut the corner of with a metal hand saw in about 3 minutes. No need for power tools here and also make sure you protect the glass lens and this is where you hold the light when cutting.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220Headlight1_zpsc3120bb9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220Headlight1_zpsc3120bb9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220Headlight2_zpsfa5d07d3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220Headlight2_zpsfa5d07d3.jpg.html)


Here they are done, and then I painted the cut off corner in satin black

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220Headlight3_zps74875a43.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220Headlight3_zps74875a43.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220Headlight4_zps6c3cda29.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220Headlight4_zps6c3cda29.jpg.html)


Here are some pictures of the mesh I have cut out for the side bumper grills. I made a template ages ago (they are on the floor in the below photo in blue foam) and used the primer technique to help with the cutting. I didn’t cut these fully out to the shape. I left plenty of excess on 1 side. Fitting these is a bit of an art I think. When ready I will bond one edge and then when that is dry, manipulate the wire into the correct shape and bond the other side

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220SideVents1_zps596cb2c1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220SideVents1_zps596cb2c1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220SideVents2_zps666514a2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220SideVents2_zps666514a2.jpg.html)


Starter Buttons

Welcome to Paul’s starter button shop!  ;D I wanted to mention this as I don’t want others to waste £20 on buying starter buttons that won’t fit like I did. All starter buttons are pretty much the same size on the button part but they vary greatly in terms of the depth of them. The steering wheel housing that goes behind the MR2 wheel has room for the workings of the button, but this area tapers down at an angle, so if you get a button that is too long it is never going to fit.

I started out by buying button A. It looked great but as you can see at the yellow line below, it is far too long. There is no way it would fit properly in the housing let alone have space for the wire connectors.  So I tried to find a shorter one, B. my plan was to try and modify the top part as it was too long at the yellow line. I couldn’t fit it as it was as it would look weird. Then by chance I was looking again and I found the right button, C. Not too deep at all, and a proud fit type. This seemed to be 3rd time lucky for me.

Here is the eBay link for it:
http://www.ebay.co.uk/itm/111106058479?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649


(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220StarterButton1_zps451e69b9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220StarterButton1_zps451e69b9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220StarterButton2_zpsa58af29a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220StarterButton2_zpsa58af29a.jpg.html)


Arrows show the space for the bottom parts of the button and how it tapers in.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220StarterButton3_zpsb1837ea2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220StarterButton3_zpsb1837ea2.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220StarterButton4_zpse97f7aab.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220StarterButton4_zpse97f7aab.jpg.html)


Button C in place and how there is plenty of room for wiring connectors, so I am well happy.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220StarterButton5_zpsd5c2724a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220StarterButton5_zpsd5c2724a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220StarterButton6_zpsa33aa089.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220StarterButton6_zpsa33aa089.jpg.html)X

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140220StarterButton7_zps6793a360.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140220StarterButton7_zps6793a360.jpg.html)

So now I have 2 buttons I don’t need but I am not worried. I live in Essex and at the local MacDonalds drive-thru there is going to be plenty of 17year old boy racers to sell these to!
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on February 20, 2014, 11:10:31 PM
Hi Paul

Great work Paul as always mate.best build diary on here with all the tips we builders look for.

Gets people out of trouble when stuck having someone's build to look at.

No probs with the tips mate you got my number bell me anytime :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 23, 2014, 08:35:15 PM
So today was the penultimate car day before going off to be painted.  The to-do list isn’t massive but still I wanted to get as much done before it goes.

It is advisable to remove the carpet before sending to the paint shop (unless you are going to replace it) as it is a very dusty environment and it will get ruined. This is fairly straight forward. I worked from the back of the car to the front. A couple of tips:

The foot rest, there are 4 screws on this, but these only hold the plate to the plastic block, so don’t bother undoing these. The footrest will come away with a firm pull. It is held on with the 2 white catches/poppers arrowed below

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223Carpet1_zpsf9835c40.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223Carpet1_zpsf9835c40.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223Carpet2_zpsaffdb868.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223Carpet2_zpsaffdb868.jpg.html)

Other things…

The cover for the fuel flap/boot release just pops out from the workings below, freeing the carpet beneath it

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223Carpet3_zps57dd2225.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223Carpet3_zps57dd2225.jpg.html)


Also there is carpet below where the roof is stored and this also comes into the rear gloves boxes. Put the roof up to remove this:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223Carpet4_zps3eb9605c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223Carpet4_zps3eb9605c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223Carpet5_zps496f8748.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223Carpet5_zps496f8748.jpg.html)

You don’t need to undo the screws behind these legs and you don’t even need to remove them. The carpet is placed around these/behind them, so just work it out gently from around the legs

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223Carpet7_zpscb0eb810.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223Carpet7_zpscb0eb810.jpg.html)

So here is the full carpet removed

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223Carpet6_zps9de87cf9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223Carpet6_zps9de87cf9.jpg.html)

Next got the paint out and painted in satin black, the rear light brackets I did last week, and then the scuttle in the places where it could show through the scuttle cover

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223FrontWork1_zps0a7f976f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223FrontWork1_zps0a7f976f.jpg.html)

Here is my fuse box (kindly donated by Crossy, thanks again matey), so now I have a fully sealed fuse box again. I also painted satin black behind the cut-out I did last week as this would show once the under bonnet cover was back on

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223FrontWork2_zps87242728.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223FrontWork2_zps87242728.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223FrontWork3_zps120f6d96.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223FrontWork3_zps120f6d96.jpg.html)


Having got my correct headlight brackets from DNA, I looked how these fit, and worked them out for the future. The below 3 shots are all of the passenger side setup

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223HeadlightBracket1_zps64f3aa9e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223HeadlightBracket1_zps64f3aa9e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223HeadlightBracket2_zps90d20847.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223HeadlightBracket2_zps90d20847.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223HeadlightBracket3_zpsfb496de1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223HeadlightBracket3_zpsfb496de1.jpg.html)


Finished trimming up the driver side, seat belt trim cover.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223SeatBeltTrimCover1_zps3d468ef3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223SeatBeltTrimCover1_zps3d468ef3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223SeatBeltTrimCover2_zpsa06b8b1c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223SeatBeltTrimCover2_zpsa06b8b1c.jpg.html)


Masked up the area to drill holes for the rear boot badge, but decided that I will do that next weekend when I am checking the rear glass again.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223RearBadge_zps6496c13f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223RearBadge_zps6496c13f.jpg.html)


The rear upper grills were next. In my last update I had a lot of excess around the main shape of the hole on the grill. A lot of this needed cutting off in reality to get them sitting right, but it is a trial and error thing. ***Tip*** put a zip tie loosely attached in the centre to help to pull it into the holes and get in the right position. It works like a handle

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223RearGrills1_zps3a48b5c3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223RearGrills1_zps3a48b5c3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223RearGrills2_zps655c8474.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223RearGrills2_zps655c8474.jpg.html)

 
The last thing was to ensure there was no arch scrubbing on the passenger side. Did a lot of testing of this (a few drives up and down the road with my new seat installed) and I think we are all good here.  Here are some full car pictures when it came out of the garage

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223Car1_zps3fa67650.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223Car1_zps3fa67650.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223Car2_zps4bb217bf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223Car2_zps4bb217bf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223Car3_zpsb7b98c23.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223Car3_zpsb7b98c23.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223Car4_zpsef99a98d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223Car4_zpsef99a98d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223Car5_zps01fac88b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223Car5_zps01fac88b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140223Car6_zps269a62e4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140223Car6_zps269a62e4.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 23, 2014, 09:10:54 PM
Finally when the car was out today,  I did a walk around video. There is some commentary on it, talking about various bits on the car. Click on the image to play. Enjoy!  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/th_20140223DNA430After306Hours_zps8728ff31.jpg) (http://i1315.photobucket.com/albums/t597/pjlucas1/20140223DNA430After306Hours_zps8728ff31.mp4)
Title: Re: Paul's 4thirty Build Diary
Post by: cheets on February 23, 2014, 11:16:54 PM
Looking reel good Paul :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 24, 2014, 10:31:38 AM
Cheers Mark. Yes it was a good feeling getting the car out yesterday with the sun threatening to shine. Hopefully i will have my timing just right. Assembly after paint should be in good weather back at my house, just in time for June/July. It was a bit sad though knwoing that the car will leave Dad's in a couple of weeks for good, seeing as it was effectively born there! LOL  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on February 24, 2014, 11:14:11 AM
im sure your dad will deserve and get a special cruise around in it when its completed!
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on February 24, 2014, 05:31:00 PM
 ;D loving the video Paul you and your dad have done a fabulous job well done can't wait to see her in paint if a picture speaks a thousand words then that video speaks a bibles worth thanks for sharing love this build thread so detailed  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on February 24, 2014, 06:44:13 PM
yes ile second that paul its a credit to you and your dad.get it finished and enjoy your build and look forward to seeing it at some shows.

Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on February 24, 2014, 07:33:05 PM
Great job Paul it'll be a totally different beast when it comes home in that gorgeous glossy giallo modena?  :P

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on February 24, 2014, 08:39:13 PM
Beany, he has already signed up to the Rosso club. Great work Paul. Looks great and now the worst part of the build. Waiting for her to come back, but when she does turn up, it's a great feeling and you will have a mega smile on your face. Well done mate.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 24, 2014, 08:48:38 PM
Beany, he has already signed up to the Rosso club. Great work Paul. Looks great and now the worst part of the build. Waiting for her to come back, but when she does turn up, it's a great feeling and you will have a mega smile on your face. Well done mate.

Hey Rudy, definitely in the Rosso club yeah (but let's not start another debate about colours! we're all good friends here LOL) . The car hasn't gone just yet, 7th March is D-Day, or should I say DNA-Day. Got one more day's work budgeted before she goes to check rear glass again and drill holes for boot badge. But now I can really start thinking about nice, pretty things such as car stereo's!  8)
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on February 24, 2014, 08:53:21 PM
No colour wars mate. We all agree that these cars look great in any colour.
Yes, stereos, sat nav. Enjoy  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 24, 2014, 08:55:44 PM
on the subject of car stereos, Dad is gonna take the old factory one out tomorrow, but is the MR2 just a standard double DIN size hole that needs filling?
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on February 24, 2014, 09:13:13 PM
nope...the hole is bigger...you need some plastic side bits. have a look on ebay you should be able to find them....
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on February 24, 2014, 10:24:41 PM
do you mean something like this?

http://www.ebay.co.uk/itm/160880281405?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

to be honest i am not that bothered about a double din one. i don't have any CD's anymore and you can now buy radios where the front flips down leaving a space for you place your iphone/ipod inside it after connecting it to a lead that is inside the radio. amazing. as for sat nav, i wont need it as will be in a convoy to the shows!!!

i might look to buy a plate something like this so it can take just a single DIN:

http://www.ebay.co.uk/itm/360860339378?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649



Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on February 24, 2014, 10:43:18 PM
thems the babies!
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on February 25, 2014, 08:30:42 AM
I took the opportunity to go with a double DIN set up on my 430 which gave me sat nav and reversing camera.  The New Furrari has gone further.  DAB radio, micro SD card, customisable splash screen and the ability to fit a tyre pressure monitoring system.
Title: Re: Paul's 4thirty Build Diary
Post by: cheets on February 25, 2014, 09:25:00 AM
Furrari that sondes like what i have got and i am fitting a reversing camera :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 01, 2014, 08:53:25 PM
Time for an update folks, as it has been nearly a week! LOL

Last weekend I brought a ton of stuff back from Dad’s to mine, ready for the reassmbly, so during this week I spend a lot of time, cleaning parts up and wrapping them to be stored ready for when they are needed. Below is some fo the stuff ready to go back on the car when the time comes.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140228CarParts1_zps4924dc63.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140228CarParts1_zps4924dc63.jpg.html)

I also brought the carpets back and spent a good 30 mins hoovering it out. In hindsight, always best to remove the carpet right at the start of the project  ;D. Here they are nice and clean

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140228CarParts2_zps1a40439c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140228CarParts2_zps1a40439c.jpg.html)

Next I added some foam to the rear part of the speaker mounts I made a while ago. These are screwed to the bare metal of the door so with the foam inbetween I will have a nice contact and should avoid any unnecessary vibration. Arrow shows the foam added.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140228SpeakerMounts_zpsa1377f4d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140228SpeakerMounts_zpsa1377f4d.jpg.html)

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 01, 2014, 09:27:41 PM
So today was the last time I got up at an unearthly hour to go over to Dad’s to work on the car. Today I treated myself to a lie in, so I arrived ready to work at 6am. The to-do list was pretty short really, but wanted to make sure I got everything done before it goes away.

One thing I did look at was the Anderson clamp. I have bought a trickle charger that I am going to have the ends connected directly to the other end of the Anderson clamp. However, practically speaking the way I have mounted my Anderson clamp inside the car on the bumper, it is not the best. (See Video shot last week)  It takes a bit of force to slide the ends together and this is very difficult doing it through the hole behind the rear number plate, especially as the clamp is mounted at right-angles, lengthways with the bumper bar. What I am going to do is not have the clamp permanently fixed to the car like it is, but have it so it is clipped to the car, and then I want to use it, I unclip it and pull the actual clamp through the rear number plate hole and connect it together outside the car. Details will be put on here when it is done of course but this can be done after painting.

The rear diffuser is going to be painted along with the rest of the car, so wanted to ensure this was all as I wanted it. One thing about the mounting here is the diffuser is meant to fit snug up again the main body work of the car. However the danger here is you have fibreglass rubbing against each other. This will cause squeaks as well as scratching. So you should fit a small u-channel rubber seal over the edge of the diffuser lip to a) stops the potential squeaks and rubbing and b) it bridges any gaps between the two that would be visible. In hindsight you should put these rubber edges on when you fit it for the first time, as it adds thickness and makes the diffuser sit further back.  So I spent some times enlarging the holes I had drilled in the main bodywork where the diffuser is secured to account for this. Very pleased with the results:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140301Diffuser1_zpsb1575339.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140301Diffuser1_zpsb1575339.jpg.html)

Here in the arrows you can see the seal, if you can’t then that is even better!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140301Diffuser2_zpsdd106e0d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140301Diffuser2_zpsdd106e0d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140301Diffuser3_zpsd0e653da.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140301Diffuser3_zpsd0e653da.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140301Diffuser4_zps2166a315.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140301Diffuser4_zps2166a315.jpg.html)

Now, it wouldn’t be a good day’s work without some sort of bracket made, so not failing to disappoint, here is another one! I had added bracket to each side of the diffuser to stiffen up both the car body and the diffuser but I noticed that in the middle it still had some wobble. This could catch the wind and wobble a lot at speed. I vaguely remember Cheets doing something like this, so I had a look around. There is this thread underneath the car in the centre that could be used to hold a bracket and thus support the diffuser in the middle:

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140301Diffuser5_zps5fad9a5b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140301Diffuser5_zps5fad9a5b.jpg.html)


Here’s today’s bracket (metal courtesy of ToolStation):

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140301Diffuser6_zps56b93881.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140301Diffuser6_zps56b93881.jpg.html)

Here are the holes marked for where it will bolt to. You want to bolt the bracket on the inside, but the only way to drill the holes is by taking the whole thing off!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140301Diffuser7_zpsaebc9abe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140301Diffuser7_zpsaebc9abe.jpg.html)

Here is the bracket bolted – I only used the hole nearest to the rear edge of the diffuser in the end.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140301Diffuser8_zps52f9ae7d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140301Diffuser8_zps52f9ae7d.jpg.html)

View from the underside. I used a lovely Allen bolt and washer as I don’t mind these showing as I think they look lovely.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140301Diffuser9_zps2935b490.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140301Diffuser9_zps2935b490.jpg.html)

Now the whole structure is rock solid.  Then I took the whole thing off again, as don’t want it to catch when I load the car next week onto the trailer. Brackets will all be painted black while it is away.


Two weeks ago when I was doing the rear light brackets, I ran out of metal to make the 3rd one for the outer lights. I had planned to do it when the car was back, but as wheel were off to do the rear diffuser, I thought I’d quickly knock these up so it is done. So now every light is secured using using all 3 bolts

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140301Lights1_zps8b031671.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140301Lights1_zps8b031671.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 01, 2014, 10:07:25 PM
So the last jobs for the day were checking the rear glass fitment again and drilling holes for the rear boot badge. (Eeek!)  :-\

I had spent a lot of time on the rear glass fitment a while ago, but Dad wasn’t there. So today we checked again together and all is well. There is plenty of wiggle room for paint and sealant, so that is all good.

I also wanted to do the rear badge with the glass in place as it has the Ferrari writing/logo on the glass and wanted to ensure all lined up and looked ok.

So to the badge. The one I am talking about here is the Ferrari script badge. I have a genuine item and these have 3 prongs at the back. The most secure way to mount these is how they are originally intended to be, but it does mean drilling holes through the rear deck. While this is scary as the margin for error is very small (due to the writing on the badge is so bloody thin!) it is slightly less nerve wracking if the car hasn’t been painted first. So this is why I wanted to sort this now.

I had masked up the approximate area last week, (masking tape is a must here) so now it was a case of careful measuring. What you need to be aware of is there is a lot of metal beneath where you want to mount this badge so you need to ensure you are going to clear it (for the prongs) before you drill. Have a good look around (again it helps if the rear glass is not present for those doing this after painting) as you can get a tape measure in an work out exactly where the metal ends so you are clear to drill. In my diagram below the metal runs to 9cm below the top of the fibre glass part (without the rear window). The metal is shown below by the yellow box area.  (***Please Note*** these are my measurements and you must measure you own car first and not rely on mine solely as yours could be slightly different)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130301BootBadge1_zps8b9602af.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130301BootBadge1_zps8b9602af.jpg.html)

So I drilled the centre hole at 10cm down. It was close but it cleared and should be able to get the badge cap on underneath.  I used a 3.5mm drill but in the end I made all holes larger to account for paint and adjustment. If you use the masking tape enlarging the holes is fine. Better to start small and get bigger.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130301BootBadge2_zps3be1b900.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130301BootBadge2_zps3be1b900.jpg.html)

Next is to drill the two outer ones. ***PLEASE TAKE CARE*** On my badge, the outer prongs are slightly lower than the middle ones. This is great for access from the other side to avoid the frame metal, but not good it you mark them up the same as the middle one in a continuous line. The best way is to dab some paint on the ends of the prongs and then try to position it, so the pongs touch the masking tape and then you have your marks. Here are the holes drilled. Note at the arrows the outer ones are slightly lower

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130301BootBadge3_zps6cde28c5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130301BootBadge3_zps6cde28c5.jpg.html)

Badge fitted: the rear deck is slightly curve from left to right (hump in the middle) so the badge has to fit this curve. Nothing major what-so-ever though.  Arrow shows the Ferrari logo on glass.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130301BootBadge4_zpsadb2a7f2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130301BootBadge4_zpsadb2a7f2.jpg.html)

Here are the prongs poking through from the other side

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130301BootBadge5_zpsc8b4e298.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130301BootBadge5_zpsc8b4e298.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130301BootBadge6_zps0da869f3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130301BootBadge6_zps0da869f3.jpg.html)

Here are the caps that fit to the prongs to the underside. They have a plastic part with is like a seal that goes right up to the fibreglass stopping any water going through the hole. If you put them on the prong they are very hard to get off, so don’t bother until you are ready to fit the badge permanently

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130301BootBadge7_zps80b8378a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130301BootBadge7_zps80b8378a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130301BootBadge8_zps8207116e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130301BootBadge8_zps8207116e.jpg.html)

Here you can see the black line show how the middle prong is out of line with the outer ones

(http://i1315.photobucket.com/albums/t597/pjlucas1/20130301BootBadge9_zpse1466286.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20130301BootBadge9_zpse1466286.jpg.html)

So that’s it. I am now happy that all the jobs I wanted to do before it’s painted have been done, I don’t think there is really anything else I could have done. Yes it does take longer doing it this way, but it makes the reassembly much, much quicker after painting and (hopefully) with no major surprises. Hope you’ve all enjoyed the journey so far….plenty more to come!!!   ;D ;D ;D ;D
Title: Re: Paul's 4thirty Build Diary
Post by: tbag on March 02, 2014, 09:59:27 AM
great work paul, fair play :)
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on March 02, 2014, 10:07:45 AM
Great build, great detailed tread and looking forward to the next stage. Bring on the colour  :)
Well done mate. A credit to you.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 02, 2014, 10:09:56 AM
great work paul, fair play :)
Cheers Tony. See you Friday.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on March 02, 2014, 11:10:38 AM
Nice work as allways the foam on back of speaker pods was a nice touch can't wait to see her in paint you've both worked very hard and deserve a great car well done  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 04, 2014, 09:26:38 PM
Just a quick update. In my last post I discussed about the Anderson clamp on the bumper bar and how I wanted it to be removable so the clamp could be pulled through the number plate hole and physically connected to the other end outside the car as it was awkward through the access panel. So I needed a suitable sort of fixing to enable it to be detachable, yet secure.

So I had a think and I found these cabinet ball catches on eBay which I think would be perfect. The smaller part would be screwed to the clamp and the larger part to the bumper bar.  I have a large Anderson clamp so I went for the largest catch I could get which was a 70mm one

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140304AndersonClampCatch1_zps3be3e627.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140304AndersonClampCatch1_zps3be3e627.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140304AndersonClampCatch2_zps9f75605a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140304AndersonClampCatch2_zps9f75605a.jpg.html)

Here you can see the smaller part of the catch. The fixing holes on the catch line up perfectly with the Anderson plug holes as well. Result!! So this will be bolted to the plug

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140304AndersonClampCatch3_zps08574819.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140304AndersonClampCatch3_zps08574819.jpg.html)

It will work like the below: the arrow below is where you can adjust the tension so it is even more secure

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140304AndersonClampCatch4_zps4094d6dd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140304AndersonClampCatch4_zps4094d6dd.jpg.html)

Simples!

Other news, the planning permission for the garage extension has been approved and work will hopefully start this week. Had a long chat with the builders last night and my door widening proposal will work. Better still they think we can do away with the frame of the door altogether and bolt the doors directly into the new brick work making it wider still. So that is all good news.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on March 04, 2014, 11:09:58 PM
sounds good Rudy,
all finished off with a new electric insulated roller shutter door 8) I used Autoroll from Washington co.Durham or somewhere in that neck of the woods. I can recomend them good product good price delivered in three days.
If you need your car out of way and safe when you start building, drop it off at mine
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on March 04, 2014, 11:11:48 PM
oops just noticed this is on Pauls build thread, sorry Paul
MADMAN :-[
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 04, 2014, 11:12:48 PM
No worries matey. Thought you'd been on the sherbets!
Title: Re: Paul's 4thirty Build Diary
Post by: sundog on March 04, 2014, 11:15:28 PM
I may not commeny alot but im always reading pal. Very good thread cannot wait to see this done.
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on March 04, 2014, 11:16:44 PM
No worries matey. Thought you'd been on the sherbets!
Correct hic, ;) ;)
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on March 05, 2014, 08:06:20 AM
That plug arrangement is so simple.  It's brilliant. 
I'll look at adding that to The Furrari at a later date.  If I ask Roland to add anything else to the build he might hit me.  Stoneleigh date is slipping.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 05, 2014, 10:00:46 AM
Mick, I know, it was very satisifying finding a solution with such readily available parts, so quickly. Makes me feel all warm inside...  ;D

Sonny, thanks mate, no worries on posting...I don't expect replies/comments, but it is always nice to get them. I know people are reading as the view count is going up!! LOL
Title: Re: Paul's 4thirty Build Diary
Post by: kalifornia on March 05, 2014, 10:11:14 AM
Lots of thought is going into your build, keep it up.
Can we get more pics and write up on the Anderson plug system as you complete it.

Still don't know why anyone has not solved the problem on the mr2's battery being drained after 3 days of standing ? If anyone has found the secret let me know. Other cars can stand for weeks without significant loss of battery!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 05, 2014, 10:20:33 AM
Kal, Anderson plug all wired up back in October 2013. full details on page 23 of my diary (about halfway down)

http://www.dnaoc.co.uk/index.php/topic,3496.330.html

Enjoy!  8)
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on March 05, 2014, 10:34:29 AM
Lots of thought is going into your build, keep it up.
Can we get more pics and write up on the Anderson plug system as you complete it.

Still don't know why anyone has not solved the problem on the mr2's battery being drained after 3 days of standing ? If anyone has found the secret let me know. Other cars can stand for weeks without significant loss of battery!

Never had a problem with mine draining, but I use a trickle charger if I know the car is gonna be parked for more than a couple weeks.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: kalifornia on March 05, 2014, 11:56:20 AM
When you get a chance beany can you see what amps is showing when you put a amp meter in-between the battery and battery cable. Just want to see how much current should be using when doors closed& locked and ecu has gone to sleep.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 06, 2014, 08:49:31 PM
So the day has finally arrived. Tomorrow is DNA-Day. If I am this excited now about dropping it off to be painted, God-knows what I am going to be like when i have to go an pick it up! LOL.  ;D

So far in time it has been 11 months, but more importantly 310 hours work. I know I have probably done more than most before paint but this is the way I always planned it.

So I've hired a self-drive transporter and me and Dad are going up tomorrow morning.

Here is a little present for the DNA boys, (well mainly Brian really  ;) )

Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on March 06, 2014, 09:17:41 PM
I would have loved to see you there but this Friday is the only day this week I'm not available.

I know the excitement.  Best wishes.
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on March 06, 2014, 09:30:07 PM
great stage to be at with your build mate....well done!!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 06, 2014, 09:49:59 PM
Mick, that's a shame but they'll be plenty more opportunities to meet up again I'm sure.
Phil, cheers mate. It's a great stage and you'll be there too before you know it.
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on March 07, 2014, 02:26:59 PM
So the day has finally arrived. Tomorrow is DNA-Day. If I am this excited now about dropping it off to be painted, God-knows what I am going to be like when i have to go an pick it up! LOL.  ;D

So far in time it has been 11 months, but more importantly 310 hours work. I know I have probably done more than most before paint but this is the way I always planned it.

So I've hired a self-drive transporter and me and Dad are going up tomorrow morning.

Here is a little present for the DNA boys, (well mainly Brian really  ;) )


I bet you dont sleep tonight ;D . how long will it be away for paint? more sleepless nights, but it will be worth it when you collect your gleaming baby.
Love the present for Brian ;D give cupcake my regards ;) ;)
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on March 07, 2014, 06:16:57 PM
We'll let us know how it feels when you have to wave goodbye to it and only to return back and find her in a new colour and looking great and ready for the final stage of the build. Excitement.
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on March 07, 2014, 06:46:48 PM
 ;) well done Paul them cakes look tasty  :P
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 07, 2014, 09:38:04 PM
Well, another mile stone has been reached in my journey today. The car was successfully transported and dropped off at DNA to be painted. Very much an action-packed day. On the road at 7:15am to go and pick up the car transporter, then to Dad’s to load the car. Everything when smoothly and we set off for Birmingham at 10am. Got there at 1pm. Unloaded the car, and spent about 1.5 hours with the guys going over things and then left for home. Big thanks to Dad for accompanying me and taking lots of pictures and especially helping when I was taking the car on and off the truck! It was a bit scary! The car was getting attention even when I was loading it on the truck by the locals, and on the journey, plenty of rubber-neckers and even some taking photos on their phones!!  When I got to Birmingham, one local shouted – it’s a Ferrari!

Here are some pictures of my day:


Loading up

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint1_zpsc1a28c01.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint1_zpsc1a28c01.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint2_zpsb569db4c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint2_zpsb569db4c.jpg.html)


Stopping off for a coffee somewhere on the M1

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint3_zps8422a2f1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint3_zps8422a2f1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint4_zps17ac72e2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint4_zps17ac72e2.jpg.html)


Arriving at DNA

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint5_zps9343ce5d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint5_zps9343ce5d.jpg.html)


The guys giving the car the once over

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint6_zpsdf1627df.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint6_zpsdf1627df.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint7_zpse397537f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint7_zpse397537f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint8_zps069ffef9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint8_zps069ffef9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint9_zps969ef69b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint9_zps969ef69b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint10_zps91413f31.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint10_zps91413f31.jpg.html)


The presentation of the cupcakes

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint12_zpsf26c7fb4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint12_zpsf26c7fb4.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint13_zpsbdf8e460.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint13_zpsbdf8e460.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint11_zps5d2da378.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint11_zps5d2da378.jpg.html)


Petrol flap needs some work

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint14_zps34041151.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint14_zps34041151.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint15_zps5328a87b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint15_zps5328a87b.jpg.html)


Roland going through the brake set up with me

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint16_zpsd8692fec.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint16_zpsd8692fec.jpg.html)

So as we turned to leave the guys has already started work on it. Good work guys! See you in a few weeks!

(http://i1315.photobucket.com/albums/t597/pjlucas1/20140307TriptoPaint17_zps63d95b04.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20140307TriptoPaint17_zps63d95b04.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on March 07, 2014, 10:43:20 PM
Only one shouting "it's a Ferrari" and the locals taking pictures.  You wait 'till you start driving it!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 07, 2014, 11:42:01 PM
Here's the obligatory video. Mainly of the car being loaded on and off the transporter...:o Click on the imagine to play. Enjoy!  ;D

(http://i65.photobucket.com/albums/h229/pjlucas2/th_20140307DNA430GoestobePaintedEdit_zps2acb0ac4.jpg) (http://i65.photobucket.com/albums/h229/pjlucas2/20140307DNA430GoestobePaintedEdit_zps2acb0ac4.mp4)
Title: Re: Paul's 4thirty Build Diary
Post by: johnjames on March 07, 2014, 11:44:23 PM
Hi Paul thank you for a good build diary you are a credit to us all I took my 430 out on the road this Wednesday for the first time had to take my sister from Ashford in Kent to Heathrow airport the car was amazing on the way back from the Heathrow got caught in a traffic jam on the M 25 and could only do 35 mile an hour the amount of people that slow down to take photographs and a car slowed down on the outside and two of the ladies in the car flashed their boobs at me, off all my years of driving I have never had that happen, anyway I hope the same thing happens to you good luck and hope to see you at Stoneleigh take care  J J
Title: Re: Paul's 4thirty Build Diary
Post by: Brian (DNA Automotive) on March 08, 2014, 12:21:18 AM
Hi Paul thank you for a good build diary you are a credit to us all I took my 430 out on the road this Wednesday for the first time had to take my sister from Ashford in Kent to Heathrow airport the car was amazing on the way back from the Heathrow got caught in a traffic jam on the M 25 and could only do 35 mile an hour the amount of people that slow down to take photographs and a car slowed down on the outside and two of the ladies in the car flashed their boobs at me, off all my years of driving I have never had that happen, anyway I hope the same thing happens to you good luck and hope to see you at Stoneleigh take care  J J

Do you know what ,....funny thing happened today when driving home from work I got the same tits out treatment off a lady ( but I was only in my fiat multipla )
Guess some of us just don't need them fancy cars!!.....
Title: Re: Paul's 4thirty Build Diary
Post by: johnjames on March 08, 2014, 09:19:34 AM
Hi Brian, when you were driving and got a flash did you have a double chocolate cupcake in your hand at the time because that really turns the women on love the reply see you at Stoneleigh and I will bring a box of cupcakes with me, keep up the great work all the best J J
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on March 08, 2014, 09:41:43 AM
Hi Paul thank you for a good build diary you are a credit to us all I took my 430 out on the road this Wednesday for the first time had to take my sister from Ashford in Kent to Heathrow airport the car was amazing on the way back from the Heathrow got caught in a traffic jam on the M 25 and could only do 35 mile an hour the amount of people that slow down to take photographs and a car slowed down on the outside and two of the ladies in the car flashed their boobs at me, off all my years of driving I have never had that happen, anyway I hope the same thing happens to you good luck and hope to see you at Stoneleigh take care  J J

Do you know what ,....funny thing happened today when driving home from work I got the same tits out treatment off a lady ( but I was only in my fiat multipla )
Guess some of us just don't need them fancy cars!!.....
                                                                    ...........just Cupcakes ;D
MADMAN ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Brian (DNA Automotive) on March 08, 2014, 12:15:13 PM
Hi Brian, when you were driving and got a flash did you have a double chocolate cupcake in your hand at the time because that really turns the women on love the reply see you at Stoneleigh and I will bring a box of cupcakes with me, keep up the great work all the best J J


Ok ...so I've got to confess she was showing them to everyone and yes she did look a little deranged. .......nice tits though ! (I probably do need a ferrari)
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on March 08, 2014, 03:29:27 PM
 ;D wow loved the video Paul cars look so much better in 3 dimension you can really see how good she looks well done and thanks was on the edge of my seat when you were loading her onto the trailer I'd have jumped out just as you did to get a better veiw on proceedings  :D nice to see dna head quarters was that furraris new beast lurking in the corner
Title: Re: Paul's 4thirty Build Diary
Post by: Wizard on March 08, 2014, 08:48:22 PM
Paul, great video.

Must admit my heart did skip a few beats when you was reversing out of your garage and then again when you drove onto the transported.  But it all worked out well for you, and your car looks great. 

Quick question, is that garage going to be the permanent home for your 430, as once the mirrors are on it will make your car even wider, and possibly more difficult to get out of the garage.  May need a lift up type door.

And yes, I thought the same thing about Furrari's car in the corner at the end.  It look look a lot like the rear end of a California, but I didn't think they were that far ahead into the project.   
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on March 09, 2014, 08:23:22 AM
Yes it's the New Furrari in the corner.  The vidio was of Paul's car not mine and I would not expect him to even mention the Furrari while he is acting like an expectant father.

DNA have been kind enough to let Luke (Trim Tech Solutions) take the inside out of the car at their place.

We are all on a steep leaning curve about the inner workings of an SL.

Watching the vidio of you reversing out my heart was in my mouth as I waited for the sound of scraping FG.  Real Reginal Molehusband stuff.

Hope it's finished in time for the day of sun we call the summer.  The thril of roof down motoring in a Furrari is impossible to describe.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 09, 2014, 05:47:07 PM
Thanks for all the comments guys

Yes it was very nerve wracking getting the car on and off the trailer. It was very close on the front bumper when putting it on, but with some adjustment to the wooden planks on the ramps it was  a lot easier when taking it off when we got to DNA. Definitely need to have the rear-diffuser off as it would hit the ground when reversing off.

Reversing out of the garage was a close call, but Wizard, no the car will not be being stored there. That was my Dad's house, and when it comes back painted it will come to my house. The reason why it was so awkward there was because the only way to fit the car in at Dad's is to have the car at a slight angle inside the car port. Which makes getting in and out of the opening much more difficult as you can't drive the car in through the gap square. Luckily back at my house i'll be able to drive through the garage door hole perfectly square so we should be all ok.

Mick - I didn't mention the Furrari build as it was not my place to  :), but yes, it is hard to ignore the beast of a car the SL is, and yes there are tons and tons of wires in that car!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 11, 2014, 08:48:54 PM
If anyone has tried to look at my build diary lately they would have noticed that none of my photos are now showing up. (Thanks Phil for pointing this out) This, while is a bit of a problem, is not forever. I have just exhausted the bandwidth limit on Photobucket for this month (probably due to that last video) but this will sort itself out in around 10 days time. So for now I will have to resort to the old fashioned way of posting pictures...
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 11, 2014, 08:51:03 PM
The car has been at DNA for 2 days now and here is some of the work they have done on day 1. Tidying up various gaps, neatening things up etc... thanks to the guys for sending over the photos and please keep them coming.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: base on March 13, 2014, 06:07:46 PM
Nice video pal, good to get a glimpse of the california. Was that red car a scuderia 16m? (MR2 based scudo)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 19, 2014, 10:12:11 PM
It’s been quiet on my build diary for a while, but I assure you I have been working hard and taking pictures along the way! So time for an update!

I’ve mainly been painting various bits and bobs while the car is away so that they can just be fitted once the car is back.

Diffuser brackets – the arrowed one is the centre bracket

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Painting1_zps00fac464.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Painting1_zps00fac464.jpg.html)

Various other pieces: dummy brake parts, pods, exhaust surrounds, front bumper ducts, rain diverter, scuttle cover, steering wheel parts, grills,

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Painting2_zps74c66f32.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Painting2_zps74c66f32.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Painting3_zpsd39df3a5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Painting3_zpsd39df3a5.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Painting4_zps90d1e6c0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Painting4_zps90d1e6c0.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Painting5_zps0100c759.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Painting5_zps0100c759.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Painting6_zps25bbd4f8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Painting6_zps25bbd4f8.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Painting7_zps0a78985b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Painting7_zps0a78985b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Painting8_zps498eace8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Painting8_zps498eace8.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Painting9_zps5502f844.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Painting9_zps5502f844.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Painting10_zps8e9c3860.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Painting10_zps8e9c3860.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Painting11_zpsc78a7cea.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Painting11_zpsc78a7cea.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Painting12_zps776f11d5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Painting12_zps776f11d5.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Painting13_zpse1b65e73.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Painting13_zpse1b65e73.jpg.html)

Once done, the pieces are wrapped up and put away for when the time comes to fit them for real. Everything has been trial fitted before so should be not too many surprises during the reassembly.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 19, 2014, 10:23:36 PM
Also big thanks to Phil for a) his write up on front headlights and b) texting me to say mine were wrong. They definitely were wrong so I sorted these out.

Below you can see the screws and the black caps clipped over the actual screw heads (circle)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Lights1_zpsc140e0af.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Lights1_zpsc140e0af.jpg.html)

Then the back plate pops on and they look like below. The one on the right is how I had it before but it is wrong.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Lights2_zps80feb429.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Lights2_zps80feb429.jpg.html)

I have more, but photobucket seems to have gone wrong... so will have to wait for another time... night night
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on March 19, 2014, 10:32:24 PM
that tough black paint is looking really nice!!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 19, 2014, 11:16:03 PM
yeah i am really pleased with the tough black paint. seems a good find
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 19, 2014, 11:21:24 PM
I also covered the pieces that sit beneath the LED strip lights in the headlights with metal tape after drilling an access hole for the wires. Not sure it is really needed if you are using LED strip lights but can’t do any harm

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Lights3_zps0367f225.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Lights3_zps0367f225.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Lights4_zps2cab6833.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Lights4_zps2cab6833.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Lights5_zps89e69938.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Lights5_zps89e69938.jpg.html)

Finally I always thought the rear number plate lights were very dim, so I have bought some replacement LED type bulbs. They should emit a nice bright light.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140319Lights6_zpse854f69f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140319Lights6_zpse854f69f.jpg.html)

Title: Re: Paul's 4thirty Build Diary
Post by: cheets on March 20, 2014, 12:00:04 AM
Looking good Paul  on the scuttle cover have you used a textured pant ?
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 20, 2014, 07:45:53 AM
Hi Cheets, on the scuttle cover I used the same tough black paint. This is acrylic satin black. I used filler primer in places before hand as well. In the photos the black paint is still wet. I am pretty pleased how the paint has turned out. 

I have spent a lot of time on this scuttle cover but not 100% happy with it. I think I am going to re do it from scratch later on as when I was cutting out the centre grill bit I just destroyed the grill. I'd like to do what you and Phil have done and reuse that bit and stick it bit further in so it looks more factory. I have toyed with the idea of using mesh on this one but really it needs the bit that has been cut out.  Will have to go back to the MR2 shop (that's Crossy btw!)

However what I have is good enough for now so I will see how it goes and how much it annoys me once back on the car. Obviously when the bonnet is shut you can't see the centre bit but there are slight imperfections on the cover elsewhere where it was scratched and where I have filled you can see slightly the marks. Standing 1 metre away from the car you wouldn't see it. But I know it is there. Like I said I'll see how it goes. LOL.
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on March 20, 2014, 09:20:47 AM
hi paul

black parts look great buddy.

the scuttle panel did you use a texture first before paint.it comes in aerosols fine or course i used a course one with wider nozzle fan and you use it before the black paint and it gives back the grained texture look of standard and also hides any small imperfections then you spay it black and it will look all even and nice.
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on March 20, 2014, 11:29:08 AM
Paul,
I copied off cheets and basically cut the front grill off, then removed more of the opening to the air intake and I am then going to bond the grill back on...that is, if I can find it!
it has mysteriously disappeared from my garage!

...I will probably also need another scuttle to get the grill from that, I will have another look for it this weekend.....saving all these jobs for when car at paint shop.
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on March 20, 2014, 01:38:45 PM
A up Phil,
              If you cant find your mesh for grill, guess what, I have some you can have
MADMAN
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on March 20, 2014, 04:43:45 PM
how did I know you were gunna say that? :-) cheers mate, Im sure it must be there somewhere...I even went through the garage bin!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 20, 2014, 10:45:09 PM
Stereo. In the end I went for the double din one. This one was at a price I couldn't refuse, half price as it was end of season stock and when I went to pick it up, there was a further tenner off! Bargain. Main thing for me was the bluetooth function and streaming my iphone songs straight to it. Will put full details on installation when the time comes
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 20, 2014, 10:47:18 PM
hi paul

black parts look great buddy.

the scuttle panel did you use a texture first before paint.it comes in aerosols fine or course i used a course one with wider nozzle fan and you use it before the black paint and it gives back the grained texture look of standard and also hides any small imperfections then you spay it black and it will look all even and nice.

Cheers for the tips and advice everyone. If and when I redo it, I will use them. For now it is OK but only time will tell!!!  Hoping to get some pictures of the car tomorrow to post up. The car has been away for 2 weeks now..  :'(
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on March 21, 2014, 10:05:23 AM
That's similar to the one I have in the New Furrari.  If it can accept a reversing camera it will also take a tyre pressure monitor.  The blue tooth part is bril.
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on March 21, 2014, 10:12:08 AM
Nice choice of stereo Paul will look really smart :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 21, 2014, 10:35:27 AM
That's similar to the one I have in the New Furrari.  If it can accept a reversing camera it will also take a tyre pressure monitor.  The blue tooth part is bril.

not sure it would take a camera Mick. it doesn't have a screen like yours had. i was tempted, but tbh as long as it plays music i am happy... for £130 i was well happy...it's been a long time since i bought a car stereo, last time was over 10yrs ago in my old 3 series beemer E30.. my word, they certianly have moved on since then!!!! LOL
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on March 21, 2014, 01:43:35 PM
Changed over the last ten years?  They have, but your starting to sound like me, an old wrinkly. :-)

M
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 21, 2014, 09:55:55 PM
Speedo Dial Backs

I thought as my wife was out I’d make myself useful and fit the Ferrari speedo dial backs.

Here is the MR2 speedo with the Ferrari dial backs

(http://i65.photobucket.com/albums/h229/pjlucas2/20140321Speedo1_zps1a21daf7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140321Speedo1_zps1a21daf7.jpg.html)

First release the clips arrows to remove the clear screen part. Just work your way around the unit releasing one-by-one

(http://i65.photobucket.com/albums/h229/pjlucas2/20140321Speedo2_zpse3a1b124.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140321Speedo2_zpse3a1b124.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140321Speedo3_zps0fa0e5ea.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140321Speedo3_zps0fa0e5ea.jpg.html)

The do the same with the black clips to release the black part

(http://i65.photobucket.com/albums/h229/pjlucas2/20140321Speedo4_zps40cd711f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140321Speedo4_zps40cd711f.jpg.html)

On the dials, make yourself a reference point where they lie on the unit so when putting the dials back you know where to put them.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140321Speedo6_zps14c9cdf7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140321Speedo6_zps14c9cdf7.jpg.html)

On the rev counter and speedometer dials I carefully lifted the dial over the stop pins and then took a photo. To remove the actual dials use 2 teaspoons (see further below)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140321Speedo5_zps7accccad.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140321Speedo5_zps7accccad.jpg.html)

With all 4 red dials removed the MR2 dial back should just pull off. Just be careful as it is stuck in places, so gently prise it off

Remove the 2 resting pins and put into the Ferrari dial backs

(http://i65.photobucket.com/albums/h229/pjlucas2/20140321Speedo7_zps312b7b5a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140321Speedo7_zps312b7b5a.jpg.html)

Add the Ferrari dial back in place, and the put the red dials back onto the unit at your reference points and gently lever over the resting pins.

When removing the red dials use 2 tea spoons (the Beany method) and gently prise them off like below:

(http://i65.photobucket.com/albums/h229/pjlucas2/20140321Speedo8_zps14eb8136.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140321Speedo8_zps14eb8136.jpg.html)

Fitting is the reversal of removal

(http://i65.photobucket.com/albums/h229/pjlucas2/20140321Speedo9_zpsb051a8c3.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140321Speedo9_zpsb051a8c3.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140321Speedo10_zps7f0bc120.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140321Speedo10_zps7f0bc120.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140321Speedo11_zps4440113b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140321Speedo11_zps4440113b.jpg.html)

All done. I’m sure the speedo one will need some tweaking due to the enlarged wheel/tyre diameter on the car, but this is for another day and will need sat nav to do it. When you do that all you’ll need to remove is the clear cover part.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 22, 2014, 03:01:27 PM
***Question Guys***

When attaching the clear lens strips to the main headlight surround unit what is the best adhesive to use? Hot glue from a glue gun, clear stikaflex type stuff? Cheers. Paul.
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on March 22, 2014, 03:22:13 PM
Making great progress Paul.

I think I used a hot glue gun, then sealed everything up with clear silicone.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on March 22, 2014, 05:24:35 PM
 :D those clocks look fab Paul  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 22, 2014, 07:37:18 PM
Cheers Beany for the answer. Will get myself a hot glue gun. Thanks for the comments Geoff. Yes I am pleased with the clocks. Hopefully from now on it is all about the finishing touches.

Also looks like my bandwidth has been reset back to zero on photo bucket so all my photos are now appearing again

Garage extension is nearly done aswell. 1 more week and it will be done. I'll have a few weeks to get it ready for the car's return.

This week I am starting to paint the headlight surrounds and then I will build up the headlights.

Also I should receive my discs and calipers from DNA so I can do some work on those aswell.

The car went into the paint shop last Friday but unfortunately nothing has been done on it all week as the painters have been short staffed and had more urgent jobs on. Hopefully they'll make a start next week. Looks like I'll be lucky to get it back before Easter now.  :'(


Title: Re: Paul's 4thirty Build Diary
Post by: seriph on March 23, 2014, 01:14:29 AM
knowing you, I bet that stereo will be fitted to look better than factory  -  think I may need to do a "research" trip over to the Uk at some stage .... might have to take a few high-level meetings ahem .... all about work of course .... ahem ... with you lads ;)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 23, 2014, 06:45:39 AM
STEVE! where have you been? Welcome back matey. We've all missed you. Yes that research trip sounds very interesting and very important of course. You'll have to arrange it around the weekend of Stoneleigh  ;)
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on March 23, 2014, 06:51:36 AM
hey mate  -  thanks! I have a new job that is keeping me away from the home fires a LOT  .... isn't it always the way though? Plenty of time - not enough cash, or .... I still visit as often as I can but just can't get much downtime. Work is awesome fun though and well paid  ... I can still hardly believe I am saying BOTH of those in the same sentence

;)

Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on March 23, 2014, 08:29:36 AM
Thanks for the bit on the speedo.  This is a job I have to do on the New Furrari, a job I am dreading.  I think this will give me the confidence to give it a go.

M
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 30, 2014, 10:19:30 PM
Time for an update. Still painting bits and bobs - now started on the headlight surrounds and steering wheel centre plate. I'm going for silver in the steering wheel plate to be like the real car. Head light bezels have been painted silver and then lacquered and now masked up ready to paint the rest of the surrounds satin black. Called in at the trimmers on Saturday, to drop off the horn button as I am having the air bag cover done in black leather. He's started the seats and all will be done in 3 weeks. Pictures are a bit boring but we all like pictures  ;D


(http://i65.photobucket.com/albums/h229/pjlucas2/20140330Paint1_zps61ae2fae.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140330Paint1_zps61ae2fae.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140330Paint2_zps113b715d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140330Paint2_zps113b715d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140330Paint3_zps6379ed8b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140330Paint3_zps6379ed8b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140330Paint4_zps2a7f5506.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140330Paint4_zps2a7f5506.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140330Paint5_zps537629dd.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140330Paint5_zps537629dd.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140330Paint6_zps36d8fde2.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140330Paint6_zps36d8fde2.jpg.html)

Silver bezels finished

(http://i65.photobucket.com/albums/h229/pjlucas2/20140330Paint7_zps243ca17a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140330Paint7_zps243ca17a.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140330SteeringWheel1_zps03bb8790.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140330SteeringWheel1_zps03bb8790.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140330SteeringWheel2_zpsfb5dc6cd.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140330SteeringWheel2_zpsfb5dc6cd.jpg.html)

Masked up bezels ready to prime and paint the rest satin black

(http://i65.photobucket.com/albums/h229/pjlucas2/20140330Paint8_zpsf9b709a9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140330Paint8_zpsf9b709a9.jpg.html)




Title: Re: Paul's 4thirty Build Diary
Post by: cheets on March 30, 2014, 11:28:02 PM
Looking good Paul and yes your right love pics can not make my mind up what i am going to do with my lights yet but i am a long way of it :)
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on March 31, 2014, 12:19:00 AM
Nice job Paul,
                    I use proper masking paper as I was told the news print contains silicone and can cause imperfections in the paint,
dont know how true it is, but worth bearing in mind in future, may save problems.
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on March 31, 2014, 11:37:49 AM
 ;D you've got to love this build thread every step has been covered well done Paul keep up the great work she's going to be awesome  :o
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on March 31, 2014, 01:13:46 PM
thanks for comments guys..

MADMAN, yes I know what you mean about the print. I don't think I need to mask anything up further and the bits that did have nespaper on them, i have re-primered anyway so I should be ok. But will bear it in mind for future.

Dummy discs and calipers I think have arrived today so can make a start on these as well...

I have gone for the ceramic style discs - these are a dark grey colour, but do people paint these normally? I plan to drill out the holes in the discs but not sure about the painting side of things. Is it worth it?
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on March 31, 2014, 05:24:05 PM
Hi Paul,
Great work on everything.
With regards to the discs. I did not paint mine but rubbed the surface with a bit of sand paper to take the shine off and make them look used. Gives a more non plastic look.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 02, 2014, 01:34:36 PM
Guys, I have a question regarding the front suspension on my car. i have used all the dna supplied parts and the car seems a little high still at the front judging by the by the gap between the arch and top of tyre. . does this really lower itself down after driving it a while? normally how long does it take and what is it that actually casues the car to lower "as if by magic" LOL  ;D . i have driven the car up and down the road a few times but nothing seems to have chnaged. or it is heavy braking from speed that causes it to lower itself?  thanks in advance guys...Paulie
Title: Re: Paul's 4thirty Build Diary
Post by: kalifornia on April 02, 2014, 03:20:07 PM
rubbed mine with a bit of sandpaper to get some scratches to look like a real disc. :)
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on April 02, 2014, 03:33:15 PM
Kal
Can we take the user name change as some form of commitment. :-)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 02, 2014, 10:37:49 PM
Just a few picture updates on my painting. Touched up the Manettino switch with red enamel paint and put the last coat of satin black on the headlight surrounds. Installed switch and sticker

(http://i65.photobucket.com/albums/h229/pjlucas2/20140402Painting1_zps5d1c2c84.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140402Painting1_zps5d1c2c84.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140402Painting2_zps4fa8bb9f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140402Painting2_zps4fa8bb9f.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140402Painting3_zpsdce53e72.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140402Painting3_zpsdce53e72.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140402Painting4_zps939ef84e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140402Painting4_zps939ef84e.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140402Painting5_zps0e84c33d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140402Painting5_zps0e84c33d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140402Painting6_zps1efcf22e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140402Painting6_zps1efcf22e.jpg.html)

My dummy Brake Callipers have come, so started work on these. Sadly on 2 of my callipers one Allen bolts has not come out properly in the mould, so I have no choice but to file it down and replace it with real bolts. I had planned to do this anyway but the other 2 callipers are pretty much spot on.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140402Brakes1_zpsa64cdad3.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140402Brakes1_zpsa64cdad3.jpg.html)

Ones with the arrows have the middle bolts filed down. I will see how these turn out, and may do the same on the 2 good callipers anyway. You know how I love my Allen bolts!!!

(http://i65.photobucket.com/albums/h229/pjlucas2/20140402Brakes2_zps78648f2b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140402Brakes2_zps78648f2b.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on April 02, 2014, 10:57:34 PM
Looking good mate.
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on April 03, 2014, 08:28:52 AM
Detail, detail all the way Paul. Excellent work my friend.

I posted quite a bit of details and photos when I rebuilt my dummy calipers, which I'm sure you've already seen. Looks like you don't have the problem I did with removing the moulded allen bolts leaving holes that needed filling.

Make sure you go for stainless allen bolts and nuts as you don't want any horrid orange spoiling what is sure to be a great finish. ;D

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 03, 2014, 08:43:15 AM
Cheers guys, yes Beany, i was a bit worried about the holes showing once the fake bolts were filed down. I had a look at Rudy's and saw that he didn't quite file it down completely flush, so i went the same way. should look fine once done. I've ordered the bolts already and yep i went for stainless steel. I knew you had rebuiilt yours, but haven't read in detail. perfect timing. something for the train ride home tonight...
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on April 03, 2014, 02:45:49 PM
Don't sleep past your stop, lol.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Mario on April 03, 2014, 06:55:16 PM
Hiya Paul79 , on the dummy brake discs was you thinking of putting the little plates under the stainless bolts like Beemaman has on his DN8 ?
I've had some made in stainless steel with a 3.2mm hole in centre , there is 40 in total .
If you want some or picture sending please contact me. Cheers Mario.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 03, 2014, 10:36:26 PM
Hi Mario, I know what you mean. I am just going with M5 Allen bolts and washers for these parts. But thanks for the offer  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 03, 2014, 10:42:03 PM
Started to bling up the callipers as the large Allen bolts arrive today to replace the filed down ones. I must admit now I have done these 2 I think I'll do the 2 good calipers as well so they all match

(http://i65.photobucket.com/albums/h229/pjlucas2/20140403Callipers1_zps79832b5e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140403Callipers1_zps79832b5e.jpg.html)

I think anymore bolts would be too much. I know there are more bolts than the real ones, but I like em. LOL  ;D

(http://i65.photobucket.com/albums/h229/pjlucas2/20140403Callipers2_zps393192de.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140403Callipers2_zps393192de.jpg.html)

In terms of sizes of these bolts I have used, the big ones are M10's and the other are all M5's. They all have washers under neath them to cover any gaps, spread the load and avoid scratching the paint once the final fitting happens.
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on April 04, 2014, 01:32:47 PM
It's your car Paul build it how you like it that's what I say looks good mate  ;)
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on April 04, 2014, 01:55:08 PM
The bolt detail is what makes them look more convincing to the uninformed.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 04, 2014, 03:06:44 PM
Just had a photo from the trimmer's. This is what the seat faces will look like. Hopefully Dad can call in next week to take some more photos.
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on April 04, 2014, 03:34:35 PM
Love the seat colour Paul nice choice  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 04, 2014, 03:37:35 PM
Cheers Geoff, yes I wanted a light colour, and was originally going to go for tan, but seemed too dark/orange.. The trimmer had loads of colours all broadly the same, but then this one came up and was called 'Ferrari Biege' so it HAD to be that one! it was fate!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on April 04, 2014, 04:05:33 PM
Looks great Paul.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 04, 2014, 04:44:23 PM
apart from the seat faces, all other stictching will be double in red. here is an example.

Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on April 04, 2014, 07:37:17 PM
That seat bit looks good.

I had long discussions with my trimmer and showed him many pictures of Ferraris for ideas.  The quality even in Ferraris is variable.  The main variation is in the stitching running across the seat and the centre rib being pulled out of shape by that stitching.  Your seat shows no sign of distortion in this area.  Good work.

It think it is great that we can pick "errors" in the original and "correct" them in our replicas.
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on April 04, 2014, 09:03:23 PM
Nice work on the caliper mate!

Im sure you have googled them but just in case here is a dirty real one for reference
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on April 04, 2014, 10:16:07 PM
Hi Paul great work buddy :)

Here's how I done my callers and discs
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on April 05, 2014, 06:38:40 AM
I believe that pattern's called boot stitch but may be wrong. Not for the novice I can tell ya!

As ever, your attention to detail is wonderful.

Best to you and dad from downunder :)
Title: Re: Paul's 4thirty Build Diary
Post by: crossy on April 05, 2014, 08:42:09 PM
Hi Paul,

Seats look great mate. Just wanted to say a quick hello on the forum as well as haven't been on for ages! Seems too many people want Sunbeds this time of year so have been working 24/7!!  Can't wait to see the pictures of your car when it comes back from paint!! :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 06, 2014, 07:30:25 AM
Welcome back stranger!  ;D I hope you've caught up. Last time you were on we were on page 43. We're now on page 53!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 09, 2014, 10:33:56 AM
More dummy brake work last night...

First the drilling out of the holes on the discs. Jeez, there are a lot of holes! LOL.  I used a 5mm drill for this. Anything smaller and the hole is too small. Anything bigger and you'll drill out the slight sunken part of the hole which is what I didn't want to do.

Disc on left is pre-drilled. One on right is drilled.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes1_zpseefd2282.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes1_zpseefd2282.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes2_zps70a249f6.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes2_zps70a249f6.jpg.html)

Once drilled, file back from the inside to remove any excess so it is nice and neat

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes3_zpsab979c71.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes3_zpsab979c71.jpg.html)

Below on right is what they look like just after drilling (yellow circle) and then once filed and rubbed down (red circle)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes4_zps98eeb6db.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes4_zps98eeb6db.jpg.html)

Next drilling out another 10 holes to bolt the centre piece (Hole-y cow batman!)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes5_zps5e04f0a4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes5_zps5e04f0a4.jpg.html)

I found it best to place the metal on how you want it and then drill one master hole using the metal as your template at 6 o'clock. (On the inside of the disc there were specific areas marked out for this, although not sure if it is purely essential they are drilled through these. I did for arguments sake) Again use a 5mm drill here and 5mm allen bolts. Then remove metal and make the hole you've just drilled a little bigger for adjustment

Then bolt it up almost tight and repeat the process in the hole directly opposite at 12 o'clock taking care to keep your metal in line. Then add another bolt and tighten them up.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes8_zps1465a715.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes8_zps1465a715.jpg.html)

Then you can go around the others and get them perfect. Drill out a hole and then put a bolt in (no need to bolt up) and move around doing one each side at a time (like you would when doing up a wheel)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes7_zpsb6506571.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes7_zpsb6506571.jpg.html)

The bolts I am using are M5 allen bolts that are 10mm long. From the back you'll see the holes you drill are so close to edge there is no room for a washer on the inside. These will be thread locked on the final fit.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes9_zpsd7a645ea.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes9_zpsd7a645ea.jpg.html)

Here's a tip, once you've done all 4 and if you are going to take them apart again, like I am to paint, then to help you remember, put a piece of masking tape on the  inside of the disc and metal and write the same number on both. Then cut tape and you'll have a marker of which goes with which for re assembly. On all the other holes I also drilled them slightly bigger for adjustment later if needed, once I removed the centre metal piece. 

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes10_zpsc0730d22.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes10_zpsc0730d22.jpg.html)

Primed up. I will paint these dark grey and then rough em up a bit (oooer!).

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes11_zpsd4cda762.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes11_zpsd4cda762.jpg.html)

Next some calliper work. I bought some brake line repair pieces. I searched on eBay after reading Beany's calliper repair thread and found these. I only bought one just in case it wasn't right. Here's the link

http://www.ebay.co.uk/itm/221061283856?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes12_zps2b38acee.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes12_zps2b38acee.jpg.html)

The pipe is 10 inch long and has a fitting both ends so my thought was to cut in half and use each piece on a calliper. I had measured that 5 inch of pipe on each would be ample. Cut and then bend. The ends where the nut/fitting is are flared so they won't come out either. 

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes13_zps238f31a3.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes13_zps238f31a3.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes14_zpsd6288ef0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes14_zpsd6288ef0.jpg.html)

Holes drilled out in the bottom of the calliper. The arrowed hole is for the copper pipe to go into to keep it steady. It will be bonded inside the calliper but I think it looks neat going into it here as opposed to just tucking behind the calliper

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes15_zps3d48ec60.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes15_zps3d48ec60.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes16_zps8f682afd.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes16_zps8f682afd.jpg.html)

Here are the first 2 done. Very pleased how these came out. Did the other 2 callipers as well and ordered another piece of pipe from eBay as well

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes17_zps0b353bb6.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes17_zps0b353bb6.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes18_zps18908447.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes18_zps18908447.jpg.html)

Here are the bleed valves fitted at the top.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes19_zps6f4438ef.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes19_zps6f4438ef.jpg.html)

One tip on your callipers. Before you begin on anything mark them up on the inside and mark an arrow to denote the top. Have a picture of a finished DNA 430 to hand for reference and carefully work out which calliper should go where and then mark on inside of them. Saves loads of time later.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes20_zpsd6ba9a7b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes20_zpsd6ba9a7b.jpg.html)

So as the fitting up is done I couldn't resist but to assemble one completely to see what it looked like. Very pleased

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes21_zps3c216d41.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes21_zps3c216d41.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes22_zps5050ea0f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes22_zps5050ea0f.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 11, 2014, 12:36:37 PM
Here are some latest pictures of the seats from the trimmer's. Starting to take shape...  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on April 11, 2014, 01:30:35 PM
WOW!

The seat part is great, but I dont think he has done a good job on the backrest  ;D ;D
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on April 11, 2014, 05:46:25 PM
 ;) well done Paul great work really love the colour leather you've chosen very classy  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 11, 2014, 05:57:09 PM
Thanks Guys. Yes I am going for the traditional Ferrari look. Red body, beige seats and silver wheels. Hope to have some pictures of the car on Monday from Brian. 
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on April 11, 2014, 08:12:53 PM
It's all coming together nicely Paul, seats are looking good. Are you having the backrest reshaped or leaving as is?

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 11, 2014, 10:56:16 PM
Cheers Beany, no I am keeping the MR2 seat shape at the top. If it could weld, maybe I would do the seat mod, but tbh i think the MR2 seats are nice and it's the easier option for me. The gap at the top will be filled in though so no holes.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 11, 2014, 11:13:28 PM
One of the problems on the MR2 factory side windows is the fact there are etched markings bearing the Toyota logo:

(http://i65.photobucket.com/albums/h229/pjlucas2/20140411Window1_zps013a76d9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140411Window1_zps013a76d9.jpg.html)

Here are some stickers I bought to try and hide them. These stick on the outside of the window as a sticker on the inside will not hide the etching marks.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140411Window2_zps3290989a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140411Window2_zps3290989a.jpg.html)

I will see what these look like on the car when the time comes

(http://i65.photobucket.com/albums/h229/pjlucas2/20140411Window3_zps7b08e63d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140411Window3_zps7b08e63d.jpg.html)

Added some rivnuts to the front and rear arch liners – what a great product

(http://i65.photobucket.com/albums/h229/pjlucas2/20140411ArchLiner1_zpsadbb1bc4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140411ArchLiner1_zpsadbb1bc4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140411ArchLiner2_zpsf4108167.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140411ArchLiner2_zpsf4108167.jpg.html)


And tonight I finished off my brake discs. I am really pleased how these came out. See before and after photo for comparisons

(http://i65.photobucket.com/albums/h229/pjlucas2/20140411Brakes1_zps178e5896.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140411Brakes1_zps178e5896.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140411Brakes2_zps9954c9d7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140411Brakes2_zps9954c9d7.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140411Brakes3_zpse1f8cb04.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140411Brakes3_zpse1f8cb04.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140411Brakes4_zps0604aece.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140411Brakes4_zps0604aece.jpg.html)

BEFORE:

(http://i65.photobucket.com/albums/h229/pjlucas2/20140408Brakes5_zps5e04f0a4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140408Brakes5_zps5e04f0a4.jpg.html)

AFTER:

(http://i65.photobucket.com/albums/h229/pjlucas2/20140411Brakes5_zps0b250372.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140411Brakes5_zps0b250372.jpg.html)

I have a spare wheel so had to try and see what it would look like…

(http://i65.photobucket.com/albums/h229/pjlucas2/20140411Brakes6_zps84606860.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140411Brakes6_zps84606860.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140411Brakes7_zpsa8fd3d55.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140411Brakes7_zpsa8fd3d55.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on April 12, 2014, 08:12:01 AM
I only had the MR2 etching noticed once.  That was by two lads for whom the sticker was at eye level.
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on April 12, 2014, 09:41:03 AM
I fitted replacement glass at aprox £50 per side, then sold OEM glass, no etching 8)
I had to shop around as most firms wanted £95 each for replacements
MADMAN
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on April 12, 2014, 09:49:31 AM
I fitted replacement glass all round.
Paul, is your windscreen original, because you will also have the same on there.

Alarm stickers look like an option. You will have to judge it for yourself and see what you are happy with. That's what matters.
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on April 12, 2014, 02:34:23 PM
I also fitted new glass all round with screen.makes for a better job and nicer finish.

Title: Re: Paul's 4thirty Build Diary
Post by: Darren on April 12, 2014, 02:36:49 PM
Wayne fitted new glass all round, I'm also fitting new glass, patten approved just shows ce  marks etc, no Toyota logo. If I remember correctly, the cost of all new glass was very reasonable.
D

Wayne beat me to typing!
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on April 12, 2014, 03:50:56 PM
Lol d

Yes new glass is a must I think all mine was around £300 with having screen and deck glass fitted no markings as d says and a new look :) also a new seal for screen same as ferrari ones

Will look great buddy
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on April 12, 2014, 07:01:38 PM
That's exactly what I had done as well.
Also had door glass and deck glass slightly tinted.
Cannot beat that new glass look with a nice paint job. :)
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on April 12, 2014, 11:08:18 PM
I took the easy option after fitting my coilovers by sticking the manufacturers decal over the Toyota markings.

beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 13, 2014, 09:38:07 PM
Just a few little jobs done this weekend

I trimmed down the head light lenses so they are flush with the headlight surround. This aids fitting of the headlights as you’ll be able to pass the whole light unit thru the actual headlight hole in the wing from the front. First I fitted the lens to the surround with the bolts and then drew around the return in pen. Then I masked up both the top and underside of the lens as I was paranoid that I could scratch it. The only tool to use doing this is a dremmel. Don’t try a hand saw as it think it could end in tears. Cover the workmate bench with a thick cloth (see photos) as well while you work and also have someone to hold the lens secure while you cut.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140413HeadlightLens1_zpse855a5ed.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140413HeadlightLens1_zpse855a5ed.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140413HeadlightLens2_zps5a2f4264.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140413HeadlightLens2_zps5a2f4264.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140413HeadlightLens3_zps7a4ef349.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140413HeadlightLens3_zps7a4ef349.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140413HeadlightLens4_zps64af3f2c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140413HeadlightLens4_zps64af3f2c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140413HeadlightLens5_zps4bf9353b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140413HeadlightLens5_zps4bf9353b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140413HeadlightLens6_zps0d6e45b7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140413HeadlightLens6_zps0d6e45b7.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140413HeadlightLens7_zpsc348c3d1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140413HeadlightLens7_zpsc348c3d1.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140413HeadlightLens8_zps604718cc.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140413HeadlightLens8_zps604718cc.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140413HeadlightLens9_zps4de33f99.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140413HeadlightLens9_zps4de33f99.jpg.html)

Also painted my exhaust access hole cover in satin black.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140413RearExhaustPlate1_zps59465921.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140413RearExhaustPlate1_zps59465921.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140413RearExhaustPlate2_zpsbf4dec1a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140413RearExhaustPlate2_zpsbf4dec1a.jpg.html)

And finally painted the dummy callipers in yellow – will lacquer them next week and then they can be assembled (blinged up) permanently

(http://i65.photobucket.com/albums/h229/pjlucas2/20140413Callipers1_zpsfe8dcfc4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140413Callipers1_zpsfe8dcfc4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140413Callipers2_zpse9919a97.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140413Callipers2_zpse9919a97.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on April 13, 2014, 10:24:54 PM
Good work mate.
It will all be worth it when you start putting it all together.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 13, 2014, 10:30:03 PM
Haha and that is when the real FUN BEGINS!!!!  8)
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on April 13, 2014, 10:53:10 PM
Looking great mate - you must be getting excited at the prospects of finally getting to drive your chariot!!!!!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 14, 2014, 05:12:48 PM
Certainly am Steve, not long now (fingers crossed)  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 14, 2014, 10:25:05 PM
Here are some pictures of the actual car.. thanks Brian for sending them over...

Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on April 16, 2014, 07:46:36 PM
 :) all that hard works finally paying of mate you must be so excited
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 17, 2014, 09:43:17 AM
certainly am matey. thanks for all your continuned comments of support.  :) it really spurs me on! yes i am now getting to the 'pretty' stage in some things which is very exciting. i hope to have some updated interior pictures today as well...
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 17, 2014, 12:20:58 PM
Dad went to trimmers this morning. Nothing new to show really i'm afraid.  :( however all the sewing on the seats and door cards is bascially done, and it just all needs assembling....this time next week we hopefully we could be done...or certainly well on the way...
Title: Re: Paul's 4thirty Build Diary
Post by: Commando on April 17, 2014, 08:09:38 PM
Wow, good work !!
Full respect to everyone who has the commitment, skill and patience to build these. OK I own one but it cant be any where near as satisfying as it is to the builder/owner. 
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 18, 2014, 10:39:18 PM
Happy Easter everyone! A couple of pictures to update you with…

The strip LEDs I had, I noticed were a bit curly. I don’t know if this is normal for such things, anyway I had the idea to straighten them up by sticking the wire from a coat hanger at the bottom to stiffen them up and then they could be bent in the correct shape for the headlight. I secured the wire with aluminium tape.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418DLRL1_zps4ed73262.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418DLRL1_zps4ed73262.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418DLRL2_zps72c4828f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418DLRL2_zps72c4828f.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418DLRL3_zps30ae0f5d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418DLRL3_zps30ae0f5d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418DLRL4_zpsa3d763d5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418DLRL4_zpsa3d763d5.jpg.html)

One done next to the other curly one

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418DLRL5_zpsb4e2f4bc.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418DLRL5_zpsb4e2f4bc.jpg.html)

They are bright as well!  8)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418DLRL6_zps2e2b0118.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418DLRL6_zps2e2b0118.jpg.html)


I bonded in the lenses for the LED lights. I used Araldite Rapid. Believe me, less is more here. All you need is 3 or 4 blobs. One at each end and then 2 in the middle and that is fine. It will hold it just fine. 

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418Headlights1_zps84a3d24e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418Headlights1_zps84a3d24e.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418Headlights2_zpsb7cb321c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418Headlights2_zpsb7cb321c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418Headlights3_zps17711c80.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418Headlights3_zps17711c80.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418Headlights4_zps132733a4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418Headlights4_zps132733a4.jpg.html)

Finished off the callipers: added bolts and valves and put Stikaflex to stop nuts coming undone. I have gone down the Beany route with the Ferrari lettering. I thought about this for a long time and looked and various pictures and after external consolations  (with the wife) I went for this way.  LOL.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418Callipers1_zps8841390b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418Callipers1_zps8841390b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418Callipers2_zpsc6967f42.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418Callipers2_zpsc6967f42.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418Callipers3_zps6f7fa9da.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418Callipers3_zps6f7fa9da.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418Callipers4_zpscd66364f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418Callipers4_zpscd66364f.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418Callipers5_zps4e56e83e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418Callipers5_zps4e56e83e.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418Callipers6_zps86495e8e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418Callipers6_zps86495e8e.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418Callipers7_zps630d0dfc.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418Callipers7_zps630d0dfc.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418Callipers8_zps0c8b9063.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418Callipers8_zps0c8b9063.jpg.html)

Starting to make up some kick boards: Thanks to Phil who told me about these and also thanks to the guy on the MR2ROC for the idea and thread:

Link to thread: http://www.mr2roc.org/phpBB3/viewtopic.php?f=47&t=30161

Templates:

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418KickBoards1_zpse68cb62f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418KickBoards1_zpse68cb62f.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140418KickBoards2_zpsa6a79f3e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140418KickBoards2_zpsa6a79f3e.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on April 20, 2014, 03:01:31 PM
Looking good Paul.

it was a strange thing with the graphics as Ferrari seem to standardise the position of the stickers they appear upside down to me.

Glad I'm not the only one.

keep up the great work and posts.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on April 20, 2014, 04:08:01 PM
 ;D :o brakes and lights look fantastic pal love the shot of the wheel and brakes together lovely :D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 20, 2014, 06:00:07 PM
Well Beany, it was you that put the thought into my head. I spent a lot of time deliberating over it. I think with the MR2 set up the claiper is even further round and down than the real thing, so they are at 5 o'clock on the front passenger side - it would be pratically upside down! . Here is a real one. I know it isn't the 430 caliper but they have the writing upside down. Mind you when googling this I did see some the other way round as well!  ;D Ah well, either way I am pleased how they look and that is all that matters!!!  8)

(http://i65.photobucket.com/albums/h229/pjlucas2/201404FerrariBrakeCalipers_zpscaf0884d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/201404FerrariBrakeCalipers_zpscaf0884d.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 20, 2014, 07:09:45 PM
Got my dummy engine out yesterday to have a look (been a while) and decided to do a bit more detailing on the engine  - painting the silver around the shield and the lines on the top of the engine (see arrows)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140420Engine_zps324829ae.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140420Engine_zps324829ae.jpg.html)

Cut out the kickboards. I won’t carpet them until I am happy with the shape when the cars is back

(http://i65.photobucket.com/albums/h229/pjlucas2/20140420KickBoards_zps4c5e1a60.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140420KickBoards_zps4c5e1a60.jpg.html)

Made some grill sticks to help with the bonding of the grills when the time comes. Each stick is approximately 30cm long and wrapped in cloth and secured with 3 rubbers bands to protect that fresh paint work

(http://i65.photobucket.com/albums/h229/pjlucas2/20140420GrillSticks1_zps95e76965.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140420GrillSticks1_zps95e76965.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140420GrillSticks2_zps4adabb7b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140420GrillSticks2_zps4adabb7b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140420GrillSticks3_zpsa77bb6d3.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140420GrillSticks3_zpsa77bb6d3.jpg.html)

Added the indicator lenses to the headlights.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140420Lights1_zps28656f6a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140420Lights1_zps28656f6a.jpg.html)

Fitted in one of the LED strips last night:

(http://i65.photobucket.com/albums/h229/pjlucas2/20140420Lights2_zps915556ec.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140420Lights2_zps915556ec.jpg.html)

Here you can see the LED strip in place and the arrow points to the metal wire I taped previously to help with the shaping of the LED strip

(http://i65.photobucket.com/albums/h229/pjlucas2/20140420Lights3_zps64c70430.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140420Lights3_zps64c70430.jpg.html)

I worked my way along securing the LED strip with metal tape

(http://i65.photobucket.com/albums/h229/pjlucas2/20140420Lights4_zps78e9175a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140420Lights4_zps78e9175a.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140420Lights5_zpscc619132.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140420Lights5_zpscc619132.jpg.html)

I then tested it all and it works lovely. I was very pleased. I thought about using the supplied cover in the kit (you’d use this if you were using a single bulb) and decided that is wouldn’t add much value (it is arrowed below), so then I just covered the metal tape with waterproof black duck-tape instead to seal it all up.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140420Lights6_zps9b0d2309.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140420Lights6_zps9b0d2309.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140420Lights7_zps192a710a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140420Lights7_zps192a710a.jpg.html)

I fitted the lights on the other side, but as luck would have it, the last 3 LED’s where I trimmed it must have a slight poor connection so they don’t light up. They come on if you fiddle but I don’t want this headache, so I ordered some more. I did know about this last week but thought I’d see if when securing them in, they worked, but alas no. Never mind, the job only takes 10 minutes to re-do.

Also added some foam to fill the gap when the lamp goes into the housing to stop flies coming in etc. I had tones of that draught excluder left so put 4 layers on and that was enough, leaving adjustment room.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140420Lights8_zpsa344d3bf.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140420Lights8_zpsa344d3bf.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140420Lights9_zps2f06739a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140420Lights9_zps2f06739a.jpg.html)

Then in preparation of the car coming back I made a sign to protect that fresh paint:

(http://i65.photobucket.com/albums/h229/pjlucas2/20140420Sign_zpsc69868bc.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140420Sign_zpsc69868bc.jpg.html)

And then I got onto sports direct and ordered 2 pairs of tracksuit bottom shorts….LOL

I cleared the garage out and this is what we are left with. Here you can see the extension at the front. The arrow points to the original door frame.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140420Garage_zps4e40982f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140420Garage_zps4e40982f.jpg.html)

Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on April 20, 2014, 07:49:24 PM
loving the tracksuits sign!!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 20, 2014, 07:51:51 PM
Haha - thought you would. If anyone one want's it, I've attached it here! LOL!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 21, 2014, 09:03:54 AM
Well, you can tell I am running out of things to do on the car as I have made these 5 slideshows of my build.  ;D  It did bring back a lot of good memories looking at the some of the earlier pictures. Ideally the slide shows would be better with music but dont want to have copyright issues.


DNA 430 Build Diary Part 1: http://youtu.be/L1kKCB3j3iQ

DNA 430 Build Diary Part 2: http://youtu.be/2dYSDSiGeMY

DNA 430 Build Diary Part 3: http://youtu.be/bZMo358rMdw

DNA 430 Build Diary Part 4: http://youtu.be/XRx62Xj7m6U

DNA 430 Build Diary Part 5: http://youtu.be/dST3_bVtgVs

Enjoy!  8)
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on April 21, 2014, 11:21:52 AM
Ha, know what you mean about Copyright issues, YouTube gave me grief over the "Black and Yellow" track over my first walk around videos. :P

I had to complete an online form saying i wasn't profiting from the video in anyway, or something like that.

lol.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on April 21, 2014, 03:31:09 PM
 :) thanks for the slide show made my day can't wait to see the beauty in paint  :D
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on April 21, 2014, 10:47:30 PM
Ha, know what you mean about Copyright issues, YouTube gave me grief over the "Black and Yellow" track over my first walk around videos. :P

I had to complete an online form saying i wasn't profiting from the video in anyway, or something like that.

lol.

Beany ;D
Sounds like I,d be to blame again (black and yellow) ;D
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 22, 2014, 12:10:12 PM
Latest car pictures - cheers Brian  8)
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on April 22, 2014, 12:44:00 PM
 ;D lovely can't wait to see her in colour  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on April 22, 2014, 04:48:09 PM
Ha, know what you mean about Copyright issues, YouTube gave me grief over the "Black and Yellow" track over my first walk around videos. :P

I had to complete an online form saying i wasn't profiting from the video in anyway, or something like that.

lol.

Beany ;D
Sounds like I,d be to blame again (black and yellow) ;D
MADMAN 8)

LOL!

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on April 22, 2014, 04:51:29 PM
Exciting times Paul.

i remember.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on April 23, 2014, 12:59:45 AM
Brings back memories.
Enjoy.
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on April 23, 2014, 09:22:18 AM
same here :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 23, 2014, 01:23:08 PM
more work in progress pictures.........

Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on April 23, 2014, 05:30:03 PM
 :) thanks for sharing Paul  ;)
Title: Re: Paul's 4thirty Build Diary
Post by: johnjames on April 24, 2014, 12:45:40 PM
Hi Paul when you go to fix your headlights if it's anything like mine there is a metal panel that sticks out a couple of inches behind the light I drilled a couple of holes in the metal panel so that I could adjust the headlights with a T 15 screwdriver it makes it a lot easier, if you hold the headlights up from underneath you will see how hard is to fix a screwdriver behind the lights. Not much room for your fingers hope the little tip helps see you at Stoneleigh  J  J
Title: Re: Paul's 4thirty Build Diary
Post by: johnjames on April 24, 2014, 12:48:08 PM
Hi Paul by the way, like the slideshow that you put on YouTube you make it look so easy anyway take care.  J  J
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 24, 2014, 10:44:52 PM
Thanks for the tip JJ. I will certainly bare that in mind when I get to that stage. I have already removed some metal that was on the MR2 that I think would get in the way of the set up, but yes, you raise a good point about the finer adjustment side of things.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 24, 2014, 10:58:22 PM
Time for some more pictures I think….

Thinking further ahead when the car is done and I am taking one of my daughters out for a drive, they are going to need the booster seat. So why not bling it up a bit?

I bought this for £1.95 of eBay:

(http://i65.photobucket.com/albums/h229/pjlucas2/20140424BoosterSeat1_zps8209aa1e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140424BoosterSeat1_zps8209aa1e.jpg.html)

....and I will get my lovely wife to sew it on to this:  8)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140424BoosterSeat2_zps5135994a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140424BoosterSeat2_zps5135994a.jpg.html)


You may remember I had to order some more daylight running LEDs as one side of mine weren't working properly (the last 3 LEDs were cutting out). So they turned up and it fitted a new strip into the other headlight as before. All working lovely, and then I decide to have both headlights on side-by-side and the LEDs are a slightly different light! Doh! I was sure I had ordered the same ones. The old ones are a real white light, whereas the newer ones are a more bluey-white light. As luck would have it I preferred the newer ones, so I then replaced the other side and all is now well.  8)

So now I set about attaching the lens to the headlight surround

(http://i65.photobucket.com/albums/h229/pjlucas2/20140424Headlight1_zps13a77cdf.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140424Headlight1_zps13a77cdf.jpg.html)

After giving everything a good clean and clean again, I attached the lens with the small screw bolts and nuts

(http://i65.photobucket.com/albums/h229/pjlucas2/20140424Headlight2_zpsf40b6bd0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140424Headlight2_zpsf40b6bd0.jpg.html)

And then I went around the whole edge, sealing it all with Aluminium tape:

(http://i65.photobucket.com/albums/h229/pjlucas2/20140424Headlight3_zpsf5b67978.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140424Headlight3_zpsf5b67978.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140424Headlight4_zpsbad5a37a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140424Headlight4_zpsbad5a37a.jpg.html)

Will do the other one tomorrow night hopefully

Finally some more pictures from the trimmers:

(http://i65.photobucket.com/albums/h229/pjlucas2/20140424Interior2_zps5019f8e9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140424Interior2_zps5019f8e9.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140424Interior3_zps63285756.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140424Interior3_zps63285756.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140424Interior5_zpsd430fb47.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140424Interior5_zpsd430fb47.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140424Interior1_zpscf17f372.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140424Interior1_zpscf17f372.jpg.html)

The drivers airbag below was meant to be done in black leather, but there was a mix-up. However I think it looks ok in the picture so I will see how it looks on the car and change if necessary...

(http://i65.photobucket.com/albums/h229/pjlucas2/20140424Interior4_zpse466645e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140424Interior4_zpse466645e.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on April 25, 2014, 07:43:58 AM
lovely stuff mate!!
Title: Re: Paul's 4thirty Build Diary
Post by: cheets on April 25, 2014, 05:36:33 PM
Hi bud it is is looking good  :D do you have the link for you LED's ? not that i can do anything from over hear but i just like spending lol 
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 27, 2014, 08:23:34 PM
I went to the trimmers on Saturday to have a look for myself at the work, and he’s done a great job. Here are a couple more photos.  Left him with the speaker grills and door handles so he can cut the leather and fit them up nicely.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140427Trimmer1_zps7bdc4753.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140427Trimmer1_zps7bdc4753.jpg.html)

I am still not decided on the air bag cover yet. Will see what it all looks like when all the trim is in the car.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140427Trimmer2_zps57fd8bb7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140427Trimmer2_zps57fd8bb7.jpg.html)


Also looks like the Gas Monkeys were in town as well!!! This beast has a V8!

(http://i65.photobucket.com/albums/h229/pjlucas2/20140427GasMonkeys_zps5069d114.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140427GasMonkeys_zps5069d114.jpg.html)


Also cleared the garage and tried putting a car in there, as I didn’t want the first time to drive a car into the garage to be the 430, just in case. It was a bit nerve wracking as I have never really had a car that was garaged, but it was ok. Getting out of this car was ok enough, and I could get out with the door even touching the wall.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140427Garage5_zpse560138c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140427Garage5_zpse560138c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140427Garage6_zps0ac31f2b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140427Garage6_zps0ac31f2b.jpg.html)


My mate Ray the electrician has managed to crimp on the other ends for the Anderson clamp to the trickle charger I have bought for the car.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140427Charger_zps8ca093e2.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140427Charger_zps8ca093e2.jpg.html)


Finally,  the calliper stickers I bought, I was sent one spare, so though I would bling up the Krook Lok I had! LOL  ;D

(http://i65.photobucket.com/albums/h229/pjlucas2/20140427KrookLok_zpsfd049ef2.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140427KrookLok_zpsfd049ef2.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on April 28, 2014, 08:46:11 AM
Those garage walls frighten me.  Give it a touch of class.  A bit of carpet.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 28, 2014, 12:13:53 PM
Hi bud it is is looking good  :D do you have the link for you LED's ? not that i can do anything from over hear but i just like spending lol 

Mark, the exact ones I bought don't seem to be listed anymore, but the ones below seem exactly like them - probably the same ones tbh. If they are 48cm long, you'll need to cut 3 LED's off, so check with the seller/description you can cut them.

http://www.ebay.co.uk/itm/2x-48CM-BRIGHT-WHITE-FLEXIBLE-LED-AUDI-A8-STYLE-CAR-STRIP-DAYTIME-RUNNING-LIGHT-/250943604870?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item3a6d678886

Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on April 28, 2014, 04:26:31 PM
 ;D wow that interior is soooo lovely loving the classic ferrari colours  ;)
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on April 28, 2014, 08:58:30 PM
Looks like your trimmers have done an excellent job mate.

Will they trim the hoop of your steering wheel to match? That could be a great look, different to anyone else.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on April 30, 2014, 05:19:15 PM
Looks like your trimmers have done an excellent job mate.

Will they trim the hoop of your steering wheel to match? That could be a great look, different to anyone else.

Beany ;D

I think for now I'll stick with the black steering wheel rim, as it hides the dirt! LOL!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 01, 2014, 09:00:10 PM
Right, here's the pictures I've been waiting for....

IT'S RED!!!!!

(http://i65.photobucket.com/albums/h229/pjlucas2/20140501CarRed1_zpsc79cb3cf.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140501CarRed1_zpsc79cb3cf.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140501CarRed2_zps06f32eb5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140501CarRed2_zps06f32eb5.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140501CarRed6_zpsa9ead002.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140501CarRed6_zpsa9ead002.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140501CarRed4_zps159b0ff9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140501CarRed4_zps159b0ff9.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140501CarRed5_zps49be75a3.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140501CarRed5_zps49be75a3.jpg.html)

Now I'm officially in the Rosso Club!!!  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on May 01, 2014, 09:02:34 PM
Welcome to the Rosso Club mate  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on May 01, 2014, 10:30:11 PM
Fantastic mate!!
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on May 02, 2014, 07:52:39 AM
 :D very very nice bet you can't wait to start building her back up well done Paul  ;)
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on May 02, 2014, 08:21:59 AM
And that's were the fun really starts.
It's the best part of the build. :)
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on May 02, 2014, 08:19:57 PM
Looks great mate I bet you had a grin seeing those pics :)

Bet you can't wait to get it back and start building it all up :)
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on May 02, 2014, 09:48:12 PM
Happy days! ;D
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on May 02, 2014, 09:55:46 PM
Congrats on a great colour choice 8) not long now
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 03, 2014, 08:02:09 AM
Guys

Thank you for all your kind comments and help along the way. Yes, another mile stone has been reached in this journey and not long now. I hope you all have a great time at Stoneleigh. I unfortunately can't make it. It is my sister's wedding day today so I'm a little bit busy! LOL. It's a shame the car isn't ready as you'll remember the original plan was to drive her to the church in it! Maybe if Dad hadn't had his accident we would have made it, but it is what it is. I should be done for the summer. Hooray!

Much love

Paul
x
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on May 03, 2014, 08:49:49 AM
 :)hope you all have a wonderful day Paul all the best to your dad  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on May 03, 2014, 07:20:27 PM
have a great day mate, see you at the next show.
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on May 03, 2014, 07:42:52 PM
Better to be done right, than done right away.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 06, 2014, 10:26:40 PM
Finished off the other headlight tonight. Here they both are with the lenses bolted and then all edges sealed with aliminium tape.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140506Headlights_zpsd2263221.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140506Headlights_zpsd2263221.jpg.html)

So I got the great news today that my car with be finished at the painters by the end of this week so I am picking it up this Friday! To say I am like a kid on Christmas Eve who has been extremely good all year is a massive understatement! LOL  ;D Happy Days!
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on May 06, 2014, 10:32:28 PM
Lights look great.
I think on Friday you will have a big smile on your face. Enjoy.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: wmrwl on May 08, 2014, 01:50:39 PM
Absolutely beautiful! I love the Red  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 09, 2014, 06:57:19 AM
Let's go get her!!!!!
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on May 09, 2014, 08:17:44 AM
Im excited for you mate!!

Plenty of pics please!
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on May 09, 2014, 11:19:12 AM
 ;D must be like Christmas Day  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 09, 2014, 09:49:34 PM
***********WHAT A DAY!!!!************

Well I am now home, I’ve had a few beers and the car is tucked safety away in the garage (yes, she fits! Hooray!). So this was my day:

Car as I arrived at DNA:

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8167_zps738057cb.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8167_zps738057cb.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8166_zps8bb82987.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8166_zps8bb82987.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8168_zpsd261316c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8168_zpsd261316c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8169_zps9dec8498.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8169_zps9dec8498.jpg.html)

Me sitting on the ‘DNA’ seat – I’d need a hole in the roof if I kept the seat! LOL

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8172_zps8cd47ca7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8172_zps8cd47ca7.jpg.html)

Finally got her on the transporter

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8173_zpsb3541a3f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8173_zpsb3541a3f.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8174_zpse7c79b05.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8174_zpse7c79b05.jpg.html)

And finally got her home

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8177_zps810e2a5c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8177_zps810e2a5c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8176_zpsd786af24.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8176_zpsd786af24.jpg.html)

Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on May 09, 2014, 09:56:34 PM
Looks great Paul you must be itching to get in that garage :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 09, 2014, 09:57:27 PM
So if you want to get the car off the ramps without touching the front bumper, you need to do this…

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8178_zps8032c82d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8178_zps8032c82d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8179_zps40c06765.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8179_zps40c06765.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8180_zps4dc0fc06.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8180_zps4dc0fc06.jpg.html)

She’s finally on dry land….

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8181_zps6c7c1c58.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8181_zps6c7c1c58.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8182_zps70b66daa.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8182_zps70b66daa.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8183_zpsbfdf3a4e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8183_zpsbfdf3a4e.jpg.html)

Gave the alloys a quick wash:

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8184_zpsa8a59752.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8184_zpsa8a59752.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8185_zps63dc6fde.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8185_zps63dc6fde.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8186_zps392665c8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8186_zps392665c8.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on May 09, 2014, 09:59:49 PM
FAN-BLOODY-TASTIC mate!!

Where is your rollbar surround and diffuser? did you carry them home in the cab?
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 09, 2014, 09:59:59 PM
OK so here is a load of photos (well you did wants lots Phil!! LOL)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8187_zps35fae2d1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8187_zps35fae2d1.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8188_zps4779f93b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8188_zps4779f93b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8189_zps04ac997f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8189_zps04ac997f.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8190_zps278ac817.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8190_zps278ac817.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8191_zps97b9453d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8191_zps97b9453d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8192_zps9a3b6aab.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8192_zps9a3b6aab.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8193_zpsf4624cae.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8193_zpsf4624cae.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8194_zpsa22efb3d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8194_zpsa22efb3d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8195_zps211980b5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8195_zps211980b5.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8196_zps767b68a6.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8196_zps767b68a6.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on May 09, 2014, 11:27:59 PM
Looks great mate. Well done.
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on May 09, 2014, 11:42:29 PM
First class paint job, still looks wet, very nice. Now the fun begins
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: Darren on May 10, 2014, 08:57:03 AM
Another great build, paint finish looks good. It's now lost the 'kit car' look  :)
D
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on May 10, 2014, 12:25:08 PM
 :o wow what a difference you must be so pleased looks like a proper 430 now  ;D ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 11, 2014, 09:50:26 PM
So now the car is finally home, and at my home, I am now at the mercy of the good-old British weather.  The garage is very tight and I cannot do many jobs in there so in between the rains drops I managed to get 2 hours on the car Saturday and about 4 Sunday.   

It was a strange feeling initially as I was almost scared to start working on the car for fear of damaging the paint. It just looks so good. (Does anyone else get this?) I had a mate come round yesterday (Ray the electrician) to see the car, (sadly it was in the garage) and he was speechless. He just kept laughing and shaky his head. He couldn’t believe what he was seeing. He had seen pictures throughout the build but never in the flesh. Anyway, I pulled myself together and took the plunge.

First I added some carpet to the left hand wall just in case and also to the front separating wall/board I drive up to. This should put Mick’s mind at rest.  :)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble22_zpsc17a2fc5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble22_zpsc17a2fc5.jpg.html)

First job on the car to do was cleaning, as that dust is EVERYWHERE! I gave the inside a brush and then a hoover. I recommend getting cheap packets of baby wipes. 4 packets for £3 from the supermarket as these are great to just wipe everything down and then chuck away.  Then I could take stock of what to do next…

This is what I managed to get done:

Fitted:

>Rear deck catches
>Rear deck gas rams
>Wired up rear decks release cables and emergency cables
>Exterior door handles
>Rear bumper reflectors
>Rear number plate lights with white LED bulbs
>Interior carpets
>Rear gloves boxes
>Centre console
>Footrest
>Sill trims and kick plate trims
>Wheel centre badges and Ferrari valve caps
>Speedo with Ferrari dials
>A-Pillar trims
>New gear knob after cutting off thread from the gear stick

As for the interior, yes there is a lot of plastic but my plan was to do the major bits (seats/door cards etc..) first and then maybe go a bit more to town next year.

It was certainly an eye-opener for the attention the car attracts. People walking by all stop and stare, some have a chat, and then there’s cars driving past: my road is a through road so it gets a lot of traffic and it is funny as they all slow down for a look.  This is good really, as people drive too fast down my road anyway.  So I am also doing my bit for road safety in Essex as well! LOL.  :)

Anyway below are the pictures:

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble1_zps3c5f1417.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble1_zps3c5f1417.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble2_zps50946b1d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble2_zps50946b1d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble3_zpsccda5cb5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble3_zpsccda5cb5.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble4_zps960fb342.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble4_zps960fb342.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble5_zpsd179272a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble5_zpsd179272a.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble6_zps068cb547.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble6_zps068cb547.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble7_zps9e56abbb.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble7_zps9e56abbb.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble8_zps97548039.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble8_zps97548039.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble9_zpsb294959f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble9_zpsb294959f.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble10_zpse8289aae.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble10_zpse8289aae.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble11_zps6319f18f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble11_zps6319f18f.jpg.html)


(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble12_zps74715a62.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble12_zps74715a62.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble13_zps698116f7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble13_zps698116f7.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble14_zps3e42c9fe.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble14_zps3e42c9fe.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble15_zps3b3b5b24.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble15_zps3b3b5b24.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble16_zps65d16f77.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble16_zps65d16f77.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble17_zps92b6e676.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble17_zps92b6e676.jpg.html)


So when it was time to put the car away, I took some final shots. All I can say is tyre shine makes a world of difference and should be compulsory! I’m well happy. Enjoy!  ;D

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble18_zps8aedf56e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble18_zps8aedf56e.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble19_zps7a024dd3.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble19_zps7a024dd3.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble20_zps3564bdc8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble20_zps3564bdc8.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140511Reassemble21_zps4fd80b95.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140511Reassemble21_zps4fd80b95.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on May 11, 2014, 10:00:10 PM
looks the dogs bo--cks m8, bet you dont sleep tonight ;D
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on May 11, 2014, 10:01:10 PM
fabulous!
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on May 11, 2014, 10:03:49 PM
I like the road safety bit.  Does that mean we should all drive Furraries, or still just the privileged few.

M
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 12, 2014, 09:07:49 PM
I had about half a day on the car today (in between showers!) A few more things reassembled:

Added rivnuts into the bumper bar to secure the cabinet catch that will allow the Anderson clamp to be detachable and pulled through the access hole when charging. It isn’t completely done as I need longer countersunk machine screws to attach the other part of the catch to the Anderson clamp. That can be done one evening in the garage.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble1_zpsedc570b7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble1_zpsedc570b7.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble2_zps4e04e519.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble2_zps4e04e519.jpg.html)


Fitted the roll bar surround cover, including tek screws at the back with hard rubber washers used as spacers in-between

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble3_zps221e627e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble3_zps221e627e.jpg.html)


Fitted exhaust access panel cover compete with A4 binder on each end! Note how I have the cover shorter than the raised lip on rear car so as to not interfere with the bonnet stops on the rear deck/frame

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble4_zps769b7c1b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble4_zps769b7c1b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble5_zps9ee87d55.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble5_zps9ee87d55.jpg.html)


Fitted rear number plate with the hinged surround

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble6_zps6d830f5e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble6_zps6d830f5e.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble7_zps813d643e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble7_zps813d643e.jpg.html)

3rd brake light all wired up and fitted

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble8_zpsed235845.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble8_zpsed235845.jpg.html)


Then it was time to go to the trimmers and pick up the final pieces of the puzzle. He has done an excellent job and I thoroughly recommend this guy. PM me for details if you want more information.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble9_zpsc30ba311.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble9_zpsc30ba311.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble10_zpsd4757c01.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble10_zpsd4757c01.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble11_zps516e14a4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble11_zps516e14a4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble12_zpse009eb8b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble12_zpse009eb8b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble13_zps3975e98d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble13_zps3975e98d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble14_zpsf47d6c51.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble14_zpsf47d6c51.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble15_zps810826e2.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble15_zps810826e2.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble16_zpsa276e029.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble16_zpsa276e029.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble17_zps5fd386a3.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble17_zps5fd386a3.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble18_zpsa983919f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble18_zpsa983919f.jpg.html)

After much deliberation I decided to put the driver’s seat in the car for now as I have enough with sitting on make-shift seats out of boxes/cushions. I have a cover for the seat so it will be protected, plus I have just put one bolt in so if I need to remove the seat it isn’t too much bother.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble19_zps0761e15f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble19_zps0761e15f.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble20_zps34eddf11.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble20_zps34eddf11.jpg.html)


Here you can see the dummy engine back in its rightful place

(http://i65.photobucket.com/albums/h229/pjlucas2/20140512Reassemble21_zpsb287e135.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140512Reassemble21_zpsb287e135.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on May 12, 2014, 09:18:04 PM
Like the seats.  Classic tan with the red.  Not as good as yellow and black but pretty damn good.
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on May 12, 2014, 09:26:36 PM
Lol, the feud just keeps on going.  ;)

She's looking great Paul, coming together quickly too. You'll soon be cruising down the road and stopping the traffic, not just slowing it down.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on May 13, 2014, 08:47:33 PM
Paul,

sent you a pm mate.

beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on May 13, 2014, 10:46:38 PM
What fued ;) ;)
                      Paul,s just got it 100% correct, Rosso Corsa tan interior, looks first class m8,
MADMAN  8)
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on May 13, 2014, 11:11:20 PM
No madman furrari got it wrong he meant to put white with black interior.bloody predictive txt eh furrari :)
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on May 13, 2014, 11:35:26 PM
No feud here, just enthusiasts expressing their opinions.  The best colour without doubt is the colour you like best. (Providing it's yellow). :-)
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on May 13, 2014, 11:37:59 PM
Now look what you,ve done Paul and all because you chose the best colour ;D
MADMAN ;D ;D ;D
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on May 14, 2014, 11:16:34 AM
ive got to say though i dont remember them making a song red and cream or black and white but they did do black and yellow so maybe some one is correct here :) :) although white and black are the most popular colours for a reason lol :) :) :)
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on May 14, 2014, 03:07:38 PM
HA! ;D
Title: Re: Paul's 4thirty Build Diary
Post by: DNA USA on May 14, 2014, 05:23:15 PM
Erm... Michael Jackson did Black & White...

A song that is... :-\
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on May 14, 2014, 07:01:01 PM
Yes your totally correct buddy so that must mean if jacko done it then it must be the best colour combo to have :)

Sorry Paul for hijacking thread we should open a new one about songs and colour choices.

Cars looking great buddy really nice :)
Title: Re: Paul's 4thirty Build Diary
Post by: johnjames on May 14, 2014, 11:56:39 PM
Hi Paul I agree with BEEMAMAN I think black and white are the best colour choices only because I have his old 430 car, by the way I went to a car show and there was a 360 which had a flat battery the guy opened his back number plate and pulled out and Anderson clamp but had to stick  2 screwdrivers in the two holds to fit a set of jump leads it might be worth thinking about getting another clamp and fixing a set of jump leads, I love the seats but there is no Ferrari horses on the headrests anyway good luck with the build see you soon J J   8)
Title: Re: Paul's 4thirty Build Diary
Post by: Litho on May 15, 2014, 11:23:28 AM
Johnjames..... it is possible to go OTT with horses ! ;)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 15, 2014, 12:55:34 PM
thanks for all the comments guys. glad you like the colour and interior. it did make me chuckle with all the colour banter...anyway, re: horses. I did think about them on the head rests but decided not to bother. there is going to be enough horses on the car for me.  :) although it could do with a few under the rear deck in the engine compartment LOL!
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on May 15, 2014, 02:27:24 PM
oh oh, I detect a V6 coming!!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 15, 2014, 11:02:01 PM
Lol. Nah. My mr2 has done less than 30k so need to get some use out of that first before I rip it out.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 16, 2014, 10:09:14 PM
Right, time for some more pictures: Not a great deal done this week, but finished the catch set up for the Anderson clamp, bonded in the exhaust surrounds and also built up the wing mirrors ready for fitting at the weekend.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140516Reassemble1_zps9c70ec10.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140516Reassemble1_zps9c70ec10.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140516Reassemble2_zps4727ac65.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140516Reassemble2_zps4727ac65.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140516Reassemble3_zpsa9018e36.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140516Reassemble3_zpsa9018e36.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140516Reassemble4_zpse83c7ece.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140516Reassemble4_zpse83c7ece.jpg.html)

The fit isn’t perfect but unless you really look you don’t notice

(http://i65.photobucket.com/albums/h229/pjlucas2/20140516Reassemble5_zps4ba9fda8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140516Reassemble5_zps4ba9fda8.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140516Reassemble6_zpsaedc9a3b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140516Reassemble6_zpsaedc9a3b.jpg.html)

Wing mirror build up. I used suckers from an iPhone screen repair kit to manoeuvre the mirror into place

(http://i65.photobucket.com/albums/h229/pjlucas2/20140516Reassemble7_zpse8fe1405.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140516Reassemble7_zpse8fe1405.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140516Reassemble8_zpsfe0b6562.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140516Reassemble8_zpsfe0b6562.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140516Reassemble9_zps03f398ee.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140516Reassemble9_zps03f398ee.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140516Reassemble10_zpsc6cda962.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140516Reassemble10_zpsc6cda962.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140516Reassemble11_zpsdd6df1b7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140516Reassemble11_zpsdd6df1b7.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140516Reassemble12_zps19b75645.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140516Reassemble12_zps19b75645.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 16, 2014, 10:44:09 PM
here's the video footage taken last Friday when I picked the car up

http://youtu.be/Ijef4_egA64

Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on May 17, 2014, 10:09:04 AM
Nice vid Paul, don't blame the cautious driving sat on a box like that in your freshly painted pride and joy.

She's coming together beautifully.

Beany  ;D ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on May 17, 2014, 08:00:46 PM
Looks good.  Soon be on the road.

M
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 18, 2014, 09:08:16 PM
Early start today at 6am for a 6 hour stint on the car. Nice day for it!  8)

Previously I had fitted up the Ferrari script on the rear deck. In the end I couldn't get the badge caps onto the prongs from underneath, so put a very small blob of Stikaflex on each to hold it.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble1_zps3069c7df.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble1_zps3069c7df.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble2_zps9c027adb.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble2_zps9c027adb.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble3_zps6ccacb51.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble3_zps6ccacb51.jpg.html)


So got the car out of the garage this am, and took both rear wheels off. Planned to fit both tail pipes, rear grill and rear lights – so with wheels off there is much better access.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble7_zpsc67207c9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble7_zpsc67207c9.jpg.html)


Fitted back the rear storage bin doors:  All fit lovely and snug

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble8_zps81431054.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble8_zps81431054.jpg.html)

Also fitted back outer windscreen seal which had been removed when car was being painted. Below is the car without the seal

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble9_zpsbb815553.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble9_zpsbb815553.jpg.html)


So after much adjustment on the tail pipes and also slightly repositioning one of the pipes that comes out of the silencer, I got the tail pipes sitting pretty much as I wanted. Also note the rear grill in position and hopefully sticking. I used a tighter mesh and the black plastic supplied in the DNA kit. I bonded these 2 pieces together the previous night along the edges as well as bolting together at each end as I thought it be much easier to bond in one piece. I cut a hole in the middle of the mesh to pass a zip tie through that has a stick on the inside and the vertical cloth covered stick on the outside.  I definitely recommend this being a 2 person job.  I will leave the prancing horse badge till the grill is all in place and then stick that on by hand. This is because the horse literally fills the whole gap and trying to get it right before hand will be impossible.

 (http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble13_zpsdda632d8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble13_zpsdda632d8.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble14_zpsd5765956.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble14_zpsd5765956.jpg.html)


Next I took the plunge and stuck on one of the wing mirrors. I chose to just do the passenger side. Have all you need to hand, test your mirror motors prior to fitting and key the area where the mirror sticks on the door before adding Stikaflex. Add Stikaflex to both the mirror base and the door to ensure all areas are covered. One of these spring clamps are great to get it set in position very quickly.  I added the small g-clamp afterwards. Once clamped I also added Stikaflex from the inside as well, and once the clamps are removed I will add more.  This will be clamped for a good few days. Again much better with an extra pair of hands.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble10_zps27af6d1e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble10_zps27af6d1e.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble11_zpsb5521967.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble11_zpsb5521967.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble12_zps789642d2.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble12_zps789642d2.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble15_zps9a799b56.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble15_zps9a799b56.jpg.html)


Finally added the rear lights and thread-locked the nuts in place:

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble16_zpscce1c7dc.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble16_zpscce1c7dc.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble17_zps9947df32.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble17_zps9947df32.jpg.html)


Put the rear wheels back on and then took a few pictures I took before putting her back in the garage. Sorry there is so many! I got carried away.

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble18_zpsa9fc8d99.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble18_zpsa9fc8d99.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble19_zps46b32f09.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble19_zps46b32f09.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble20_zpsc7434af0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble20_zpsc7434af0.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble21_zps4f02e140.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble21_zps4f02e140.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble22_zpsf2c0435c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble22_zpsf2c0435c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble23_zps19a1312c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble23_zps19a1312c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble24_zps273e25ec.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble24_zps273e25ec.jpg.html)


These shots are to see how the wing mirror looks:

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble25_zpsaab83cc4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble25_zpsaab83cc4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble26_zps486b5500.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble26_zps486b5500.jpg.html)


Then was time to drive in the garage. What a difference it made reversing the car and being able to look in the wing mirror!  :)

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble27_zpsf1848fc8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble27_zpsf1848fc8.jpg.html)


Loads of room (just!) Who's that loitering at the back?

(http://i65.photobucket.com/albums/h229/pjlucas2/20140518Reassemble28_zpsa9aa0d00.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20140518Reassemble28_zpsa9aa0d00.jpg.html)


Until next time… :)
Title: Re: Paul's 4thirty Build Diary
Post by: greig1983 on May 19, 2014, 11:12:10 AM
Looks really nice, well done
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 19, 2014, 11:52:46 AM
***Question Guys***

The wiring for the push button horn. I have borrowed the below picture from the MR2ROC (thanks Guys) and was wondering how i wire my Ferrari push button horn to this? I have the little white plug the is shown in the below picture with the yellow arrow. the yellow wire that comes off and connects to the metal is earth i guess? but where should my wires go from the push button horn i have? into the white plug? the wires on my button are black and yellow.

cheers

Paulie

Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on May 19, 2014, 01:42:56 PM
hi paul

i think on mine buddy i used the main positive wire to one on the horn and earthed off the steering wheel if you look theres 2 holes with threads in were you can earth them.i just tried bothe wires each way around before soldering
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on May 19, 2014, 05:28:15 PM
Paul,
Beemaman is right. Negative to metal and positive to horn wire. I remember it was trial and error to find the correct wire as it all depends on year of car and if it's an import or UK car. All are different.
Hope this helps.
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on May 20, 2014, 10:51:07 AM
The usual way of wiring a horn is to feed a supply to it via a relay and put the switch in the earth line.  This means only one wire to the switch and there is also something to do with the high voltage that can be produced by the make/break of the high frequency coil.  (Back EMF)

M
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 20, 2014, 10:52:42 AM
horn all working fine now.  ;D will post pictures later on in the week on car progress. thanks guys for all your help on this....
Title: Re: Paul's 4thirty Build Diary
Post by: sundog on May 20, 2014, 12:42:25 PM
Paul i have to say buddie this is a great detailed build , and p.s the more pics the better font be worrying!! ;d
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on May 20, 2014, 01:01:28 PM
 ;) yes the more pics the better you and your dad are building a fine replica she's a real beauty in Red :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 23, 2014, 08:31:04 PM
Been doing bits and bobs in evenings this week….

Here are some more pictures of the rear grill being stuck: There is a hole right in the middle to allow the zip tie to go through to allow it to pull the grill forward and clamp. Also from the inside I put sticks at each end to push forward the grill from the inside to help it stick at the bottom. In the middle on the inside is a garden cane that the zip tie attaches to.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8314_zps43bf6d0a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8314_zps43bf6d0a.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8315_zps476a2cc4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8315_zps476a2cc4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8316_zps4523d772.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8316_zps4523d772.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8317_zps002b8a45.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8317_zps002b8a45.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8318_zps09af1b98.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8318_zps09af1b98.jpg.html)


I also stuck on the rear horse: Mine had 2 prongs for the nuts. I cut these off as I was going to stick the badge  After covering up badge to protect it, the best way to cut is take a metal saw, turn upside down, stand up, put handle to your chest and lean the other end against the wall. Then take the badge prongs and carefully move badge back and forward on the upside down saw blade and it will cut. Then file down.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8326_zps9b4e99d1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8326_zps9b4e99d1.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8327_zps763ae6cc.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8327_zps763ae6cc.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8328_zpse65b4a84.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8328_zpse65b4a84.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8330_zpsaf81705d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8330_zpsaf81705d.jpg.html)


The gap for my horse to sit in on the grill is slightly too narrow so you have 2 options. 1) Twist the horse slightly to fit either forwards or backwards or 2) have the ears tucked under the rear lip. If you study a badge, the foot of the horse which is on the ground is directly vertically beneath the top of the head so really needs to be in line.

I didn't want a 'wonky donkey' so chose option 2. However this posed another problem. Because of the way I stuck my grill with the zip tie pulling it in the middle the top of the grill was flush with back of rear deck lip. I didn't want the ears touching the underside of the rear deck when closed as it would rub paint each time deck was opened. So I had the idea of sticking some rubber trim on the back of the rear deck lip. When it closes this pushes the grill forwards thus creating a gap. Therefore the top of the horse’s ears sit in this gap and it all looks nice and straight.  The rubber trim I used here was the stuff you remove from the rear deck glass. It is nice and thick and tough as well. Perfect for the job.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8351_zps0b09b1f5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8351_zps0b09b1f5.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8356_zps89ef4351.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8356_zps89ef4351.jpg.html)


Stuck horse on and held in place with tape. Also put a piece of card under the foot to create a small gap between badge and car.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8349_zps6029aaee.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8349_zps6029aaee.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8350_zpsebb4b1c8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8350_zpsebb4b1c8.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8352_zps1a2aee49.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8352_zps1a2aee49.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on May 23, 2014, 08:43:07 PM
you must have bought a large horse!!

Here is what a real one fitted looks like
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 23, 2014, 08:55:53 PM
I bought it off you mate!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 23, 2014, 09:13:30 PM
Steering Wheel:

I secured the rear part of Ferrari wheel to MR2 wheel using machine bolts and nuts and on one of these one of these attached an earth wire for the horn. Photos show live wire for horn in red. Connection point is arrowed in yellow.  I then connected these to the horn button.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8319_zpsbe66db11.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8319_zpsbe66db11.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8320_zps7f26276e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8320_zps7f26276e.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8321_zps2e4ed9be.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8321_zps2e4ed9be.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8323_zpscd1e731b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8323_zpscd1e731b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8324_zps68754cb0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8324_zps68754cb0.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8325_zpsb4778ae1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8325_zpsb4778ae1.jpg.html)


I attached the silver face plate using bolts that screw into the steering wheel puller holes. I then attached the air bag cover via small screws. My Manettino switch is just bolted and thread locked. The starter button is bonded into the face plate but not wired up yet. I'm of two minds whether to bother tbh. (BTW thanks again for the wiring details Beany). We'll see. Then I put it all together along with the speedo bezel cover. I'm not 100% sure about the beige airbag cover. I think it clashes with the yellow on the horn button a bit. I may swap it out for black like I originally wanted as I was going for the original black on silver look

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8340_zpsb9314692.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8340_zpsb9314692.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8341_zps3f6a9aeb.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8341_zps3f6a9aeb.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8342_zpsbba5e913.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8342_zpsbba5e913.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8343_zpsa31ab874.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8343_zpsa31ab874.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8344_zps94a1acec.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8344_zps94a1acec.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8345_zps7d089c12.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8345_zps7d089c12.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8346_zpsaff69748.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8346_zpsaff69748.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8347_zps7409dfa8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8347_zps7409dfa8.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8348_zps2bbabf39.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8348_zps2bbabf39.jpg.html)


I added back the driver’s window. Nothing special to mention here, but just put a cloth on the rough metal edges of the inside of the door to stop the glass being scratched.
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on May 23, 2014, 09:13:51 PM
lol!...ill have to dig mine out!!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 23, 2014, 09:20:48 PM
I think you'll have the same issue. The gap on the DNA is narrower than the real car. Look at the below photo: No bother. No one is going to notice...I'd rather it straight than twisted.





Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 23, 2014, 09:27:48 PM
Rear glass bonding:

Did this last night. It’s a bit of a job on your own but certainly do-able. A couple of things: 1) do the glass before you fit the grills either side as these holes where the grills go allow you to get access to the glass from underneath and move it around if need be. 2) Don’t have the dummy engine in as it gets in the way.

Obviously try the glass first and then do a dry-run with the weights you are going to put on the glass and plan where each goes. Have some of the bubble wrap the glass comes in to protect the glass from these weights. 

I keyed the area first and then added the black stuff, carefully lowered the glass on and then pressed/clamped. I will leave this for a couple of days to really set. I will then open up the deck and add more glue from the inside to fill in any gaps. Given the way the rear deck opens currently, the glass will slow it down further so it should open gently but better safe than sorry with the glue.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8353_zps19c362fa.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8353_zps19c362fa.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8357_zps74bff30d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8357_zps74bff30d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8358_zpsde01119f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8358_zpsde01119f.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8359_zps0c69f1ba.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8359_zps0c69f1ba.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8360_zpsb7299f5a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8360_zpsb7299f5a.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8361_zpsac8f81b2.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8361_zpsac8f81b2.jpg.html)

Also stuck in the grill for the rear diffuser – hope to fit this on at the weekend. Then the rear will be done.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8354_zps48b85362.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8354_zps48b85362.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8355_zps2a7eec76.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8355_zps2a7eec76.jpg.html)


Well that's it. Hope to get some more done over the weekend.
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on May 25, 2014, 03:29:09 PM
 ;) keep the pics coming your doing a grand job and I think the prancing horse looks just great  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on May 25, 2014, 03:40:27 PM
I think you'll have the same issue. The gap on the DNA is narrower than the real car. Look at the below photo: No bother. No one is going to notice...I'd rather it straight than twisted.

Aha my old 54 plate 430 that featured in two issues of kit car mag.
Good pic. of a real deal next to my DNA
MADMAN 8)




Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 25, 2014, 09:35:43 PM
I had 4 hours on the car today. Got her out again and got the back wheels off the finished the rear end! Woo hoo! Here is the story…

During the wheel I bonded the top of the rear diffuser grill once the rest of it had dried, then added the hanging brackets and a rubber trim on either side where it meets the car paintwork. I think this rubber seal is a must, even though the diffuser is pretty solid with the extra brackets I have used. You don’t want any wobble scratching the paint work.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8362_zps3c459059.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8362_zps3c459059.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8363_zps43fc7ca9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8363_zps43fc7ca9.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8364_zps65a989c5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8364_zps65a989c5.jpg.html)

I even bonded this seal in places so that it doesn’t come off

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8365_zps10c36eba.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8365_zps10c36eba.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8366_zpscc55d108.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8366_zpscc55d108.jpg.html)

Here is the view of my rear horse badge

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8367_zpsb5766b57.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8367_zpsb5766b57.jpg.html)

So Sunday morning I took all the weights off the rear deck glass and nervously opened it. The glass is well stuck and I am very pleased how it is had stuck and it is pretty flush all the way around the edges. Placed the dummy engine back in before I got the car out of the garage.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8368_zps21912321.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8368_zps21912321.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8370_zpsdc24b7df.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8370_zpsdc24b7df.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8372_zps053f6cc7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8372_zps053f6cc7.jpg.html)

Before fitting back the rear diffuser I had to sort out the Anderson clamp fixing: ***Mick*** I know you like the cabinet catch idea, but I unfortunately think now it is a non-starter. The catch is simply not strong enough to hold the clamp securely. Maybe if I had gone for the smaller clamp it would have, but I was not happy.  So been thinking of alternatives and this is what I have come up with:

The rivnuts I had put into the bumper bar, in one of them I screwed and thread-locked a 10cm M5 threaded bar – (bolt but with no head). The screwed in all the way through the rivnut and up against the other side of the hollow bumper bar. Then I added a packer washer.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8373_zps870e0b50.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8373_zps870e0b50.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8374_zps1f5ef8d0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8374_zps1f5ef8d0.jpg.html)

My thought is to let the Anderson clamp sit on the thread and then be secured with a washer and wing nut. You can do the wing nut up by hand tight enough for it to be secure enough. When you want to use the clamp, just undo the wing nut and pull the clamp off the thread and through the whole behind the number plate and connect to charge. Simples.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8375_zpsc17649a4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8375_zpsc17649a4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8377_zps59ec7d16.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8377_zps59ec7d16.jpg.html)


Other jobs done: fixed back the 3rd brake light flasher unit box and the dummy engine and strings

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8381_zps47d93fcc.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8381_zps47d93fcc.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8380_zps844dae9f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8380_zps844dae9f.jpg.html)



So next was the fitting of the rear diffuser, but before I began I was visited by V8 KLR! It certainly caused quite a stir and attracted the local “yoof” to have a look. One said to me he HAD to pull over and have a look as you never see 2 Ferraris together. The V6 on Andy’s car sounds amazing, and you can literally hear him coming from the other side of the estate!!! Was good to have a chat and compare notes on the different kits over a cup of coffee and he was a big help as we fitted the rear diffuser. It took 3 of us to do it! Thanks mate!

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8382_zps7729c240.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8382_zps7729c240.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8383_zps8d1a806e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8383_zps8d1a806e.jpg.html)

Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 25, 2014, 09:54:41 PM
So onto the rear diffuser: here are the now infamous tool station brackets all sprayed up in satin black.  The middle one is the extra one I made is for the middle of the diffuser

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8379_zpscab562fe.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8379_zpscab562fe.jpg.html)

I bolted the brackets loosely to the car body mounting points first and for the middle bracket, I also zip tied it up to pull it up higher so that when the diffuser was slid on it didn’t hit it. So here we are all fitted up. All nuts and bolts are now thread-locked as well.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8384_zps147b90f7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8384_zps147b90f7.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8385_zps8016b2a4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8385_zps8016b2a4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8390_zps80d39887.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8390_zps80d39887.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8396_zps2e9ae7c7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8396_zps2e9ae7c7.jpg.html)

Rubber seal:

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8397_zpseebb18e7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8397_zpseebb18e7.jpg.html)


Fitted back the passenger window: I was a bit worried that the wing mirror would interfere with it, but it cleared fine. I recommend fitting this window after you’ve put back the seal around the windscreen so you can adjust the angle of the window accordingly so that it seals around the window correctly.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8386_zpsd97b6aa1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8386_zpsd97b6aa1.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8387_zpsb28851f3.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8387_zpsb28851f3.jpg.html)

Wing mirror with clamps off

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8395_zps6ff3520c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8395_zps6ff3520c.jpg.html)


Then I added more glue to the inside of the rear deck glass to fill in any gaps. So now it should be very secure

I needed to maximise the time with the rear wheels off, so started the bonding of the side grills. Managed both the top ones and the passenger lower one.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8391_zps3e28ebe0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8391_zps3e28ebe0.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8392_zps2b05540a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8392_zps2b05540a.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8393_zps0e3aedc3.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8393_zps0e3aedc3.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8399_zps21d96f04.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8399_zps21d96f04.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8400_zps9ea3dc46.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8400_zps9ea3dc46.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on May 25, 2014, 10:05:08 PM
Final update of the day… fitted the roll bar hoops: 

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8389_zps5eeca4d1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8389_zps5eeca4d1.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8388_zps20b5d93f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8388_zps20b5d93f.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8394_zpsf67bb72b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8394_zpsf67bb72b.jpg.html)

So final shots after I put the rear wheels back on and her back in the garage:

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8401_zpsc063d767.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8401_zpsc063d767.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8402_zps7ee5657a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8402_zps7ee5657a.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8403_zpsb416a2ea.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8403_zpsb416a2ea.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8405_zps3832f66c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8405_zps3832f66c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8406_zps4adb67ff.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8406_zps4adb67ff.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8407_zps0a765ae0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8407_zps0a765ae0.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on May 25, 2014, 10:18:00 PM
fantastic pictures mate, it looks amazing!
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on May 25, 2014, 10:40:23 PM
Was going to do this plug set up for the new Furrari, but then I remembered that I can open the boot to get at the main battery with a key.  Silly me.

I know what you mean about the two Furraris together.  When I've driven to the hotel we use in Exeter behind Tenpin the look on peoples' faces is amazing.  The Nothern Convoy on its way to shows must attract a bit of attention.
Title: Re: Paul's 4thirty Build Diary
Post by: V8 KLR on May 25, 2014, 10:49:43 PM
Pauls car is a great credit to him and his father, the attention to detail is exceptional. Well done to both of them...spending time with your dad on something like this is really great..... ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Commando on May 25, 2014, 11:40:23 PM
Could not agree more, Fantastic joint effort !
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on May 26, 2014, 12:17:03 PM
 :) the two of you must be so proud of what you've achieved she looks awesome  :o
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 01, 2014, 05:05:27 PM
So on the bank holiday monday we had a lot of family around as it is was my daughter’s birthday, so thought I’d get the car out to show a few people before it rained. The grills had bonded well over night, so removed the support sticks. I still need to the do the drivers lower one, but the mesh I’ve cut out it too small, so I need to redo it. The others seem to come out fine

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8408_zpsbed4e2dc.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8408_zpsbed4e2dc.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8409_zps6cc0e7b8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8409_zps6cc0e7b8.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8412_zps4ca9f64f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8412_zps4ca9f64f.jpg.html)

Here is one of Dad in his Rosso Corsa shirt:

(http://i65.photobucket.com/albums/h229/pjlucas2/photo1_zps33a89ffc.jpg) (http://s65.photobucket.com/user/pjlucas2/media/photo1_zps33a89ffc.jpg.html)


And one of the dream team!

(http://i65.photobucket.com/albums/h229/pjlucas2/photo2_zpsa950a443.jpg) (http://s65.photobucket.com/user/pjlucas2/media/photo2_zpsa950a443.jpg.html)


So during the week I have been doing more little jobs: I stuck the rear deck grills next to the glass. I made loads of support sticks from pencils wrapped in cloth, secure with rubber bands. The mesh is then bonded and pulled tight using very small zip times and the cloth covered pencils.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8413_zpsf6f8ff9b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8413_zpsf6f8ff9b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8414_zpsd0dc238d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8414_zpsd0dc238d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8415_zpsd0be82bb.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8415_zpsd0be82bb.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8416_zps67d880ab.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8416_zps67d880ab.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8417_zps4bf903a4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8417_zps4bf903a4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8420_zpsd1f93052.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8420_zpsd1f93052.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8421_zpsdd491695.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8421_zpsdd491695.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8422_zpsc89ee594.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8422_zpsc89ee594.jpg.html)


Added back the door speaker surrounds and then fitted up the speakers.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8424_zps6e7b1ca8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8424_zps6e7b1ca8.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8425_zpsfb906dbc.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8425_zpsfb906dbc.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8426_zpsbe4a93d8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8426_zpsbe4a93d8.jpg.html)

More to come later...
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on June 01, 2014, 06:09:55 PM
That frighten me for a minute.  I thought it was me standing there and I didn't remember the pic being taken.  With these eyes we look scarily similar expect I haven't got a shirt like that and wear my watch on the right.  Don't be surprised when I see you at shows (soon I hope) and call you my brother.  Spooky.
You work is 100% but you didn't say what the reaction was.

M
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on June 01, 2014, 06:31:33 PM
Looking good Paul going to be lovley finished.so nice when all the little bits start coming together.

Wish I hadn't had my little setback I was looking forward to the next show :)

Keep the pics coming buddy :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 01, 2014, 08:20:51 PM
On Saturday, I wasn't happy with the way my passenger side rear deck catch was locking. It would click as if locked but wasn't secure enough, so I had a look and it turns out that the cables were too tight and thus prevent the catch clicking off to lock. So I loosened the wire slightly and it now locks securely.

Next job was the passenger wing mirror. I had removed the clamps a while ago but though it best to put some more glue on the inside of the mirror triangle.


I next started to work on the front of the car. I fitted back the scuttle cover, windscreen wipers (with built in washer jets) and also connected up all the washer jet pipes. See previous pages on my diary on how I connected the pipes up.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8427_zps3029ad13.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8427_zps3029ad13.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8428_zps0c4ab99e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8428_zps0c4ab99e.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8429_zpsa7a68ec7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8429_zpsa7a68ec7.jpg.html)


Washer jet tubing arrowed:

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8430_zps25a7c30b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8430_zps25a7c30b.jpg.html)


Gave underneath a good clean as well

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8431_zpse6941d10.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8431_zpse6941d10.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8432_zpsc1327f74.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8432_zpsc1327f74.jpg.html)



Once the washer jets were all working I fitted the under bonnet cover. I had to trim this further as DNA had kindly fitted the flitch wing brackets for me so the cover needed extra clearance.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8433_zps3a0aa319.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8433_zps3a0aa319.jpg.html)


Added the rubber that goes between the larger cover and the scuttle cover

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8436_zpsb39ce08e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8436_zpsb39ce08e.jpg.html)


After fitting back all the above I needed to tweak the bonnet catch slightly and trim down the scuttle bonnet stops as the trim as height. All now closes securely.


Next as Dad was here we removed the front bumper so I can work on building it up during the week with grills, ducts etc.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8434_zps00ac3f10.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8434_zps00ac3f10.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8435_zps58a91cdc.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8435_zps58a91cdc.jpg.html)


Finally, I started fitting up the passenger door card. I have decided to use rivnuts and bolts in the doors as opposed to screws to secure the door card. So I worked on lining these up. I used M5 x 20mm Allen bolts to secure the door cards although I have ordered some button head ones that are more flush fit.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8437_zps009d7f6d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8437_zps009d7f6d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8438_zpseaf226d9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8438_zpseaf226d9.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8440_zpsdf518d5b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8440_zpsdf518d5b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8441_zpsc120abb1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8441_zpsc120abb1.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8442_zps6855a121.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8442_zps6855a121.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 01, 2014, 09:11:23 PM
And now onto Sunday: I started the day fitting back the side indicators. The fit was nice and snug given the primer and paint in the holes. I secured the wires with zip ties but you need to allow for a little flex as when door opens is will brush the wire slightly

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8443_zps1c772beb.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8443_zps1c772beb.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8444_zps542b22c4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8444_zps542b22c4.jpg.html)


Thought I'd try fitting back the seat belt trim panel and securing the seat belt as well. To neat off various edges I fitted some u-channel rubber in places. I also added the b pillar top rubber. It needs some slight trimming but the inside trim clip hole is still there and useable. The two trim clips on the outside are redundant but I stuck the rubber down using double side tape. I trimmed one of the clips so it was still in place but flush so I didn't just leave a hole in the rubber showing. I also fitted back the sill trim and kick plate as well as door edge rubber.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8445_zps8b6bec70.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8445_zps8b6bec70.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8446_zpsa9080d62.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8446_zpsa9080d62.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8447_zps9a1312b0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8447_zps9a1312b0.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8448_zps77dc5a97.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8448_zps77dc5a97.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8449_zps660dff50.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8449_zps660dff50.jpg.html)

Trim rubber here at the arrows to soften the sharp edges

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8450_zpsed3d1b21.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8450_zpsed3d1b21.jpg.html)

Trimmed down trim clip

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8451_zps73b190ca.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8451_zps73b190ca.jpg.html)

Added back the passenger seat

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8452_zps53e8112a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8452_zps53e8112a.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8453_zpsba073b96.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8453_zpsba073b96.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8454_zps7f2d2ef5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8454_zps7f2d2ef5.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8455_zpsaf9ec373.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8455_zpsaf9ec373.jpg.html)


Next a job, I thought would take no more than 5 minutes: fitting the roof slot brackets, but NO. I had made a mistake here. The metal roof brackets that fit in the slots didn't line up with the welded threads on the frame underneath. I had cut these slots ages ago, before I had even bonded on the rear deck but never checked all was well. I cut them using the measurement in the DNA video (can’t remember the measurement now) but upon reflection it is probably best to have this measurement in mind but also do this once rear deck is bonded so you can measure from underneath as well and drill your starting centre hole accordingly. Then once you have the approx. placement you can work out the exact position. Anyway, so I had to nervously file out a larger slot on the painted deck but all was well in the end. I will fill the channels with trim next week.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8456_zpsf00eb355.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8456_zpsf00eb355.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8457_zps3d51cfec.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8457_zps3d51cfec.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8458_zpsf93297bb.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8458_zpsf93297bb.jpg.html)

While on these brackets, Brian at DNA told me ages ago when I picked up my kit, that the thread you screw the thumb screw onto to position the slot bracket can often be clogged up from the powder coating. As the thumb screw is brass, and therefore softer, it is best to screw on a steel nut on the threads first to unclog the thread and then unscrew. As it was doing it you could see tons of old paint etc.. being cleaned off so it was great advice from Brian. After that I add 2 rubber washers to centre the bracket and then attached the thumbscrew

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8459_zpsa704e997.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8459_zpsa704e997.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8460_zps575d8f00.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8460_zps575d8f00.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8461_zps3bbd7eff.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8461_zps3bbd7eff.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8462_zpsb0cac05f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8462_zpsb0cac05f.jpg.html)

The rest of the time was spent fitting back the deck pods and z-flaps. Nothing exciting here really but as you know these can take a while to line up. I am pretty happy with the gaps and next week I plan to fit the D-rubber in the right places that will hopefully even things all up.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8464_zps41f4186d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8464_zps41f4186d.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on June 03, 2014, 11:04:03 AM
 :) great car great build thread love the pic of you dad and the car ;)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 08, 2014, 09:17:00 PM
Apologies for the lack of recent updates, but I have been busy working on the car! LOL Been doing bits every evening after work and had a good 7 hours on it today.

During the week I have been gradually building up the front bumper while it has been off the car. I have added a number plate surround which is the same one as on the rear of the car. This is a very basic Mercedes one that cost £1.80 each! It is bendy enough to take the curve of the bumper. I added foam tape to the rear of it before bolting. 

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8465_zps7cecd324.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8465_zps7cecd324.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8466_zpsc527cbc9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8466_zpsc527cbc9.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8467_zps82f9b94c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8467_zps82f9b94c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8468_zpsc232d413.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8468_zpsc232d413.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8469_zpsce1f1190.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8469_zpsce1f1190.jpg.html)


I added the large grills next. You definitely want to bond these before the scoops/ducts otherwise you’ll scratch the scoops trying to get the mesh in.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8470_zpsbefa6db9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8470_zpsbefa6db9.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8471_zps9779d85f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8471_zps9779d85f.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8472_zps599203c9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8472_zps599203c9.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8473_zps5d9e664c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8473_zps5d9e664c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8474_zpsd99dee5b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8474_zpsd99dee5b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8475_zpsfe40a087.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8475_zpsfe40a087.jpg.html)


Next did the side grills. It is best to get the grill in position using the sticks and zip ties before you add any glue. That way you can get the position perfect without any mess. Once you’re happy then add glue on top of the mesh and leave to set.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8478_zpsa4bd1810.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8478_zpsa4bd1810.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8488_zps7e03051d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8488_zps7e03051d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8491_zps00d2dac4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8491_zps00d2dac4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8492_zpsabd64879.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8492_zpsabd64879.jpg.html)


Scoops

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8489_zpsbce88f7b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8489_zpsbce88f7b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8490_zps7ddc5a1b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8490_zps7ddc5a1b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8493_zpsf7716d32.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8493_zpsf7716d32.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8494_zpsf13b91b5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8494_zpsf13b91b5.jpg.html)

Centre Diffuser

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8495_zpsc3ce421d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8495_zpsc3ce421d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8497_zpsd5d045cf.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8497_zpsd5d045cf.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on June 08, 2014, 09:31:05 PM
Looking very smart mate.
Soon you will be showing it off at the shows. Can't wait to see it.
It looks great.  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 08, 2014, 09:34:17 PM
I have removed the MR2 radio using the attached guide. Big thanks to the guys who wrote this on the MR2OC as this helped me out a lot.

http://www.mr2oc.co.uk/forums/200/123673.html

Here is the MR2 Radio. It has a surround that you need to remove and keep

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8498_zpsa7a01cf1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8498_zpsa7a01cf1.jpg.html)


Here is the standard double din radio. This will also have a surround. You need to remove this as well. You won’t use this. Neither will you use the cage that comes with your new radio.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8499_zps44028f6b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8499_zps44028f6b.jpg.html)


You’ll see from removing the MR2 radio that is it bolted to the car using these brackets. You want to replicate this on your new radio.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8500_zps85842da4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8500_zps85842da4.jpg.html)


I unbolted and then added to the new radio – you should have holes for it to sit nicely and to screw into. The position of the brackets on the new radio should be the same as on the old radio.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8501_zpscded3c1b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8501_zpscded3c1b.jpg.html)


Next you’ll need an adaptor kit like the below. The MR2 radio is wider that a standard radio, and if you want to use the MR2 surround so it looks neater, they’ll be gaps at each end. The black pieces below bolt to the radio and fill the gaps.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8502_zpscf4f1b87.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8502_zpscf4f1b87.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8503_zps9f5ac116.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8503_zps9f5ac116.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8504_zpsef3ecd88.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8504_zpsef3ecd88.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8505_zpsb30130a0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8505_zpsb30130a0.jpg.html)


Here is the original surround fitted back – a nice neat finish

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8506_zpsf3fb20b7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8506_zpsf3fb20b7.jpg.html)


Here I have added the hands-free kit that came with my radio. I undid the passenger roof catch bracket and this then allowed the plastic trim to come away slightly and I fed the wire in. It goes along the top of the windscreen, down the a-pillar and then behind the glove box and into the back of the radio

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8507_zpsb3f047c3.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8507_zpsb3f047c3.jpg.html)


I have also added a windscreen aerial. I have stuck it also on the a-pillar. This will be hidden behind the trim panel. If the reception is poor, I have the option to stick it to the outside of the trim panel instead. This is amplified aerial so needed an earth and also a 12v power. In the photo below the arrow shows a hole that was already there, where I added an M5 rivnuts and then bolted the earth to it. Dont add it to the hole beneath it as this hole is where the trim clip goes into.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8513_zps482af41d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8513_zps482af41d.jpg.html)


I then fed the wire through and connected the power to the radio ignition 12v power cable so it will only come on when radio is on.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8511_zpsec8d460f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8511_zpsec8d460f.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8512_zps1346f937.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8512_zps1346f937.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 08, 2014, 09:41:01 PM
Another evening job I did this week was to change the horns. The MR2 ones are a bit ‘Noddy’ like so I got some new air, snail horns. These are a direct replacement for the originals. You need to make an earth wire which I earth to the bracket that bolts the horns to the car. The horns even come in Rosso Red!

Originals

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8479_zps2a104169.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8479_zps2a104169.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8480_zps046cdabc.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8480_zps046cdabc.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8481_zpsf768326e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8481_zpsf768326e.jpg.html)

New ones

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8482_zpsbb8d67df.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8482_zpsbb8d67df.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8483_zps9651c677.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8483_zps9651c677.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8484_zps8df772f4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8484_zps8df772f4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8486_zps097b34ca.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8486_zps097b34ca.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8487_zps87b762da.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8487_zps87b762da.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 08, 2014, 10:17:13 PM
So on to Sunday… The main task today was getting the headlights in so I could put the front bumper back on. This is a bit of a job, and definitely helps having an extra pairs of hands. Dad came over early and we got cracking.

First I lined the inside of the headlight holes with p rubber. You don’t actually see it but it helps seals gaps between the fibreglass and plastic lens.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8514_zps3df85589.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8514_zps3df85589.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8515_zps0b97098d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8515_zps0b97098d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8516_zpsf7409686.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8516_zpsf7409686.jpg.html)


Next I gave everything a good clean and refreshed myself with the setup of everything.

Here is the bracket that main headlight sits on – we called this the table bracket.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8517_zps678c37da.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8517_zps678c37da.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8518_zpsf6ab04a1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8518_zpsf6ab04a1.jpg.html)

I keyed the table and then realised that the piece of original MR2 metal was in the way when trying to add the main bulb – arrowed below, so I bent it underneath itself. This gave much more clearance

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8519_zps67c5b2c2.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8519_zps67c5b2c2.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8520_zps4b54462b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8520_zps4b54462b.jpg.html)

The best to do this is to have the table on the headlight holder bracket but not it the right position at first. Then slide the headlight unit through the hole cut out in the wing from the front. The table can then be moved to go underneath the headlight unit to support it temporarily. Then you can add the headlight bulb into the headlight unit from inside the arch and then to can put the bolts into the table to secure it to the headlight holder bracket. Sounds complicated but once you’re there you’ll know what I mean. Then comes the fun and games of adjusting it all. LOL On the actual headlight bulbs and the adjuster screws I set these to be screwed in about half way, that way if you fit it all up like this, then you know you’ll have a lot of available fine tuning adjustment afterwards. We got things all lined up and then added bond to bond the headlight unit to the table, and then did further adjustment to make the headlight unit sit nicely in the hole.

Here we did the driver’s side first. To create gaps where needed,  I used some small pieces of u-trim rubber (arrowed below) - the same stuff I used on my rear diffuser.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8521_zps1a42ad59.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8521_zps1a42ad59.jpg.html)


Here’s a view from the inside of the arch

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8522_zps76888ac4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8522_zps76888ac4.jpg.html)


Then it was a case of doing the other one, wiring all up and testing

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8523_zpsead7d7c3.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8523_zpsead7d7c3.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8524_zps2a01f83c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8524_zps2a01f83c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8525_zpsfef7e9aa.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8525_zpsfef7e9aa.jpg.html)


Here are the side light LEDs switched on

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8526_zps9ddb0756.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8526_zps9ddb0756.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8527_zps358c4441.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8527_zps358c4441.jpg.html)


Wires were tidied up and zip-tied to the original parts of the car well out of the way

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8528_zpsf1972a2f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8528_zpsf1972a2f.jpg.html)


So then it was time to add the front bumper back.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8529_zpse119e1c9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8529_zpse119e1c9.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8531_zpsa4d57d9e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8531_zpsa4d57d9e.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8532_zps7591f2a1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8532_zps7591f2a1.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8533_zps663d8f29.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8533_zps663d8f29.jpg.html)


Wheels back on, I took (quite) a few pictures and then time to put her away for another day! I’m really pleased how the lights came out as I was dreading this job but it is another milestone reached and big thanks to Dad who was tremendous help with them all.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8536_zps1d475418.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8536_zps1d475418.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8537_zps2993fc75.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8537_zps2993fc75.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8538_zps7ae9b5fe.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8538_zps7ae9b5fe.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8539_zpscee53dc0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8539_zpscee53dc0.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8540_zps77d93829.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8540_zps77d93829.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8541_zps7a630231.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8541_zps7a630231.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8542_zps5fdffb69.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8542_zps5fdffb69.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8543_zpse176626c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8543_zpse176626c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8544_zpsabb64f87.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8544_zpsabb64f87.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8545_zpsfd9992ac.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8545_zpsfd9992ac.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8546_zps3cc497c7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8546_zps3cc497c7.jpg.html)
 
Have a good week all.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on June 09, 2014, 08:55:25 AM
lots of work done there mate!!

She is nearly ready!

I will be interested in what you think about the radio reception, as I too am looking to hide the amplified aerial as I didnt like it stuck to the top of the screen.

Well done
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 09, 2014, 08:58:07 AM
thanks i will let you know about the reception. Hopefully putting radio in this week and then when car is out of garage next time, i'll see how the reception is
Title: Re: Paul's 4thirty Build Diary
Post by: DNA AUTOMOTIVE on June 10, 2014, 02:33:52 PM
Put the amplified aerial high up under the dash close to the screen ensure its grounded correctly you should have no problems
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on June 10, 2014, 05:14:59 PM
thats the thing though, I think we would both like to hide it completely if possible....
Title: Re: Paul's 4thirty Build Diary
Post by: DNA AUTOMOTIVE on June 11, 2014, 01:01:38 PM
Under the dash it will be hidden??
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on June 11, 2014, 01:30:31 PM
thats a thought! I may look at that one!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 14, 2014, 12:35:30 AM
Here are the updates on my mid-week jobs

Front number pate added to the surround

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8547_zps83fab1f8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8547_zps83fab1f8.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8548_zps0efe9d4a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8548_zps0efe9d4a.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8549_zps373db857.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8549_zps373db857.jpg.html)


Fully fitted back the stereo

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8552_zps3a85ca02.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8552_zps3a85ca02.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8554_zps3be38bb0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8554_zps3be38bb0.jpg.html)


Did a headlight alignment check – not back for the first time

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8557_zps8a0292ac.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8557_zps8a0292ac.jpg.html)


I wasn’t planning to do the dummy brakes until the car was outside but I had a thought and on the driver’s side at least there was room to take the wheels off in the garage.

Here is the rear driver’s side bracket for the dummy callipers. This fits onto the bolts that secure the MR2 calliper. These are right at the back of the hub

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8566_zps787162a4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8566_zps787162a4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8569_zpsce4a1833.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8569_zpsce4a1833.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8570_zpsfe8f1bcd.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8570_zpsfe8f1bcd.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8571_zpsf782fa29.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8571_zpsf782fa29.jpg.html)


I’ve gone for something different. I’ve gone for the 5cudo discs which are ceramic looking but with the 430 callipers. The 5cudo dummy discs are around 1cm larger in diameter than the 430 discs and you need 19 inch wheels to accommodate it all.  This also means you’ll need to bend the thread bar brackets to clear the edge of the larger discs.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8573_zps6eca98c6.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8573_zps6eca98c6.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8574_zpsa119ad21.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8574_zpsa119ad21.jpg.html)


So here is the threaded bar as it is without modification. It sits too close to the disc.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8577_zpsdffedd60.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8577_zpsdffedd60.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8578_zps214f78f1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8578_zps214f78f1.jpg.html)


So you have to bend the threaded bar in an ‘s’ shape slightly to enable it to clear. I made a couple of cuts with a saw to mark where to bend, used a vice and bent the bars.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8579_zps5f786fad.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8579_zps5f786fad.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8580_zps2fa92341.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8580_zps2fa92341.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8581_zps00b337c5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8581_zps00b337c5.jpg.html)


Now it clears. I did actually clamp the dummy calliper onto the threaded brackets to give me an idea of the amount of bend needed. Plus remember, the angle of the setup can change a lot one the nuts on the threaded bar are done up so test for this.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8582_zps07c9e6be.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8582_zps07c9e6be.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8584_zpsab254d20.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8584_zpsab254d20.jpg.html)


So then I bonded the calliper to the bracket and left overnight. It is a lot easier to bend the brackets without the calliper on. So I used the 1st bracket as a template for the other and got that ready for fit up at the weekend. In theory they should work the same.

Then I fitted it up. Have washers and nuts either side, and I put a load of thread lock on the thread before fitting up as well so they don’t change position when it is set. Always check there is no danger of it hitting the dummy disc and of course the wheel once it is back on. There is going to be some flex of course, but not a lot.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8587_zps0f75d67b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8587_zps0f75d67b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8588_zps8f6549aa.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8588_zps8f6549aa.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8591_zps9bfc52ea.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8591_zps9bfc52ea.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8592_zps41da6c22.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8592_zps41da6c22.jpg.html)


Can’t wait to get the car out on Saturday and look from a distance at them


(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8590_zps4662649e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8590_zps4662649e.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 14, 2014, 10:05:11 AM
Bonding up the callipers

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8594_zps3645dc0e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8594_zps3645dc0e.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8595_zpscc45363d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8595_zpscc45363d.jpg.html)


Front set up

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8596_zpsa7795b84.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8596_zpsa7795b84.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8597_zps18d9fbdf.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8597_zps18d9fbdf.jpg.html)


While I was here I drilled out the dimple on the headlight bracket and attached a teck screw to keep the headlight in place, should the main nut and bolt work loose.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8599_zps5af0eecb.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8599_zps5af0eecb.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8600_zps3be9f85c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8600_zps3be9f85c.jpg.html)


The front brackets for the dummy callipers need more of a bend to clear the disc. The threaded bars on the front are shorter as the spacers are not as wide on the front.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8601_zpsee1c1ed1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8601_zpsee1c1ed1.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8602_zps5e2040d3.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8602_zps5e2040d3.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8603_zps1e44acdf.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8603_zps1e44acdf.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8604_zps58deafd1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8604_zps58deafd1.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8605_zpse5a13826.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8605_zpse5a13826.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8606_zps0d873eaa.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8606_zps0d873eaa.jpg.html)


I noticed that the cable that releases the driver’s side rear catch was sticking. I had used the original MR2 set up. It turns out the when I fitted back the seat belt, the lower bolt that goes into the sill/floor, the cable was running underneath and the bolt caused the cable to become snagged and it caught. So I undid the bolt and made sure once it was fitted back the cable ran above the bolt not underneath it. Picture below isn’t great but you get the idea:

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8608_zps8608bb1e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8608_zps8608bb1e.jpg.html)


Next I pinched an idea off Phil (cheers mate) to enable me to undo the pod catches easier. I added some black cord to make a sort of handle. I tied it to the catch and then covered the ends in amalgamation tape to neaten things up. I then extended it down and tied it at the other end of the rear frame. Pictures say it all really:

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8609_zpsb3adec05.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8609_zpsb3adec05.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8610_zps674a3841.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8610_zps674a3841.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8611_zps912f0fcd.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8611_zps912f0fcd.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8612_zps8d16e4d9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8612_zps8d16e4d9.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8614_zpsd224c205.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8614_zpsd224c205.jpg.html)


Added the amalgamation tape on the dummy engine string as well

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8613_zps9de27582.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8613_zps9de27582.jpg.html)


I noticed that the battery, even with the rain drain channels could be exposed to water, so I raided the Tupper-ware drawer and found this and plan to cut and shape it to be a battery cover. Will spray satin black once ready.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8615_zps8dea9ba0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8615_zps8dea9ba0.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8616_zps660e0fa9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8616_zps660e0fa9.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on June 14, 2014, 11:19:34 AM
The details are fantastic.  I wish some of the garages I've used paid this much attention to detail

M
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on June 14, 2014, 07:19:17 PM
fantastic work yet again mate, well done.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 15, 2014, 09:18:44 AM
Hello Guys

A good 6 hours on the car yesterday but sorry, I didn’t take many photos. I basically fitted up the passenger side dummy brakes, had to do some headlight adjustment, added the teck screw on the passenger headlight brake and managed to bond the passenger upper rear duct for the induction kit. What took the time today was the rear deck cable and the upper rear duct. You need to ensure the cable goes over the top of the duct/hose rather than it being squashed by the hose otherwise the cable will catch and not work properly. This involved taking all the rear glove boxes/doors off and re-routing the cable slightly to get some extra slack. It is always a shame to undo work already done, but we got there in the end. 

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8617_zps300e97ce.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8617_zps300e97ce.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8618_zpsee8aa093.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8618_zpsee8aa093.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8620_zps746401be.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8620_zps746401be.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8621_zpsa6bb0bcd.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8621_zpsa6bb0bcd.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8622_zpsa14a481c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8622_zpsa14a481c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8623_zps272619eb.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8623_zps272619eb.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8619_zps2a003a32.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8619_zps2a003a32.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on June 15, 2014, 09:45:56 AM
 ;D love the battery box cover idea and have to say she is looking beautiful  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on June 15, 2014, 10:22:59 AM
she is defo looking awesome now with her wheels all sorted!
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on June 15, 2014, 12:52:06 PM
I like the equal gap between the wheel and wheel arch.  Sign of a good build.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 21, 2014, 09:26:37 PM
Right peeps, I hope you’re sitting comfortably…there’s a lot to get through…

Battery Cover

I marked up a basic template out of cardboard, and then cut out the lid from the Tupperware box I had. There is a thread marked in one of the photos that secures the battery, so I added a connecting nut and then added an Allen bolt and washer at the top to secure it. Put some rubber edging trim on as well to make it look a bit nicer.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8628_zpse4e59a8d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8628_zpse4e59a8d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8629_zps986fa65e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8629_zps986fa65e.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8630_zps63600c97.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8630_zps63600c97.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8631_zps835bf929.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8631_zps835bf929.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8632_zpsc359e089.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8632_zpsc359e089.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8633_zps5d318aee.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8633_zps5d318aee.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8634_zpsd8764f32.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8634_zpsd8764f32.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8635_zps524eb7d0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8635_zps524eb7d0.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8637_zps9cc93224.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8637_zps9cc93224.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8638_zps0fded02d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8638_zps0fded02d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8640_zpsc9917e0c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8640_zpsc9917e0c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8642_zpsdbb5dea3.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8642_zpsdbb5dea3.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8668_zps2b03722a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8668_zps2b03722a.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 21, 2014, 09:30:53 PM
Then during the evenings I prepared the drivers wing mirror for bonding, added the driver’s upper rear pod and also added the hose as well to this side. It isn’t massively long, but long enough to fool you thinking it is functional. I stuck this hose on with lots of gaffer tape and I have also secured it with zip ties and some black stuff as well.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8648_zps0c6af8a5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8648_zps0c6af8a5.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8646_zps19f369fd.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8646_zps19f369fd.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8647_zps4a03b00c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8647_zps4a03b00c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8649_zpsc9c3577d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8649_zpsc9c3577d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8650_zps18aa69c0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8650_zps18aa69c0.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 21, 2014, 10:03:24 PM
So this week I took a cheeky half day on Tuesday as the weather was nice and I couldn’t wait till the weekend to do more serious work. So I started on fitting back the passenger door trim. I had already added the rivnuts in the door ready for the Allen bolts I had.

I gave the door a good clean inside and out, and removed any clips that weren’t necessary. Checked all wiring was correct and that everything was working as it should

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8652_zps9e026a13.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8652_zps9e026a13.jpg.html)

Phil has given me a tip he’d read on the MR2OC about using a product called ‘flashing tape’ as an insulator. Apparently is it just as good as Dynamat, but at a fraction of the price. (Search eBay for it). It is used for roofs and it is very malleable - perfect for the contours of the door.  Just cut it in sections, peel off the backing and cover the door! Simples.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8653_zps52579468.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8653_zps52579468.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8654_zpsef701370.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8654_zpsef701370.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8655_zps6af9c110.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8655_zps6af9c110.jpg.html)

It was very easy to work with

Fitted back the door card and handle

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8656_zpsa8f97868.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8656_zpsa8f97868.jpg.html)

***Here a tip***

As you know, I added an L-shaped bracket to the door that the interior handle bolts to, so when you pull the door closed you are pulling on the door itself, not the door card. (Yellow arrow below)  That is all fine, but when to pull the lever to open the door from the inside, the front of the interior door handle lifts up. (Red arrow below)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8657_zps01273406.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8657_zps01273406.jpg.html)


There is nothing on it to stop this, so we had a think. I thought about extending the bracket I had added and having another bolt but that would be a lot of work and wouldn’t really work as you’d be drilling through working parts/ clips on the interior handle. I then had the idea to add a small screw to the front of the handle surround that basically acts as some resistance to the whole thing lifting up. It was perfect. I drilled a hole and then screw the black screw in and it as absolutely rock solid. Like factory. I was very pleased with this as it was so simple yet so effective. Screw circled below. You can hardly see it.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8658_zps4c905974.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8658_zps4c905974.jpg.html)

Unless someone else has done this already I might have to name this the “Paulie door handle screw!” LOL.

Next I connected up the induction kit hose and checked all the pipes where supported well and secure. Next was fitting up the rear arch liners. I gave the inside of the arches a good clean and then added the liners. I had previously added rivnuts to these. The rivnuts at the rear were added via bonding a metal plate that had a rivnut already in place. I was a bit wary of this as wasn’t sure whether it would hold. It seems fine, but for after all this, there is no reason why you cannot just have a nut and bolt set up. You’ll be able to reach the rear part where the nut goes easy enough.  I had to do this on one of mine. Arrow in photo below shows the cut out and the exhaust pipe freshly painted in black.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8659_zpsa49a0636.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8659_zpsa49a0636.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8660_zpsb82b57fd.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8660_zpsb82b57fd.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8661_zpsc0b3c235.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8661_zpsc0b3c235.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8662_zpsa3c3c390.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8662_zpsa3c3c390.jpg.html)

Final job of the day was bonding the driver’s wing mirror.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8663_zps86c01a51.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8663_zps86c01a51.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8664_zps97227908.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8664_zps97227908.jpg.html)

Here is the door card once the car was put away

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8665_zps713168f0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8665_zps713168f0.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 21, 2014, 10:15:41 PM
Here I changed the scuttle cover screws for ones that had caps. I just bought the black caps and the white mounting washers off eBay and used different screws. Looks much neater than the screw head showing.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8669_zps6ec9c1db.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8669_zps6ec9c1db.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8670_zpse9c9d712.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8670_zpse9c9d712.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8671_zpsdc449268.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8671_zpsdc449268.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8672_zps703009d7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8672_zps703009d7.jpg.html)


Next I blanked out the air bag warning light as this would be an MOT failure. I toyed with the idea of the resistor (thanks again Beany) but in the end I went with the blanking out option. You have to take the rear of the speedometer out (via the 7 gold screws)  and then the circuit board. It is very easy and is only a 10 minute job, but you must not have that light on!

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8673_zpsb011f2f2.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8673_zpsb011f2f2.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8674_zps6aa48a80.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8674_zps6aa48a80.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8676_zps4cd64193.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8676_zps4cd64193.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8677_zps293ab9b1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8677_zps293ab9b1.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8678_zps25e4be8a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8678_zps25e4be8a.jpg.html)

Then I added the p-rubber to the rear deck areas. I am not happy with my z-flaps and I am going to redo the hinges, but this isn’t an essential job.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8685_zps14c916fd.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8685_zps14c916fd.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8686_zps2c2cc1e4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8686_zps2c2cc1e4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8687_zpsf2b639b3.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8687_zpsf2b639b3.jpg.html)

I cut a little notch out here to help the p-rubber go around a 45 degree turn

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8689_zps3c479c87.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8689_zps3c479c87.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8690_zps6c3db5f6.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8690_zps6c3db5f6.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 21, 2014, 10:23:38 PM
My wife was looking on our photo stream and came upon the below photo and asked if i could go back to those days? mmmmmmm  - I'm not sure! A lot has changed in a year!  :)

June 2013
(http://i65.photobucket.com/albums/h229/pjlucas2/20130616FrontClip2_zps21b02218.jpg) (http://s65.photobucket.com/user/pjlucas2/media/20130616FrontClip2_zps21b02218.jpg.html)

June 2014
(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8536_zps1d475418.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8536_zps1d475418.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 21, 2014, 10:58:41 PM
So onto this morning – todays plan was the front bumper under cover, front badge and driver’s door card. Was up a 5am to get the car out and worked till around 2pm. As usual things take longer than you think but they have been worth it.

Started with a few small jobs/touches:

Added, drivers tax disc holder, driver’s door hole plate and p-rubber on passenger side.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8693_zps6c5916a4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8693_zps6c5916a4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8691_zpsf0ccd254.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8691_zpsf0ccd254.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8694_zpsa90a674a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8694_zpsa90a674a.jpg.html)

Front bumper under cover

So onto the front bumper under cover: I had fitted this up previously on the bumper but then, the bumper was off the car. On the car - it is a different ball game altogether. I chose to do this after the bumper was put on, because if this was attached before it could get in the way of attaching the bumper, which I figured was more important to get right.

I tried to fit this up in the garage last Sunday but I was not happy. I didn’t like the fact that the cover was so flexible from the edge of the bumper to the centre of the car. I knew it would just flap around when driving it. It needed some sort of bracket to firm it up – and of course the bracket could only come from one place – ToolStation! When you look under the MR2 you’ll see some fixing points from the original car. There are 3 in the middle area and then there are 2 further towards the outside of the car. I planned to use the 2 outer ones for my brackets and the centre one of the three middle ones. I planned to have basically a brace of metal from the bumper lip (red circles below) to the MR2 outer fixing points mentioned above (black circles), thus securing the bumper lip as well. The cover would be bolted to the metal in places, firming it up. The cover would fix in all the other places as before on the rest of the bumper lip. See below

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8696_zps1682bb2c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8696_zps1682bb2c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8695_zpsc32aad24.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8695_zpsc32aad24.jpg.html)

I also thought ahead here. As I would now have a nice solid bracket, the lower arch liner parts could bolt to this part. So in preparation of that I also added 2 rivnuts each side to the metal bracket so they could be bolted to these easily.  Yellow circles are the rivnuts poking through and the other fixing are the bolts securing the black plastic to the metal bracket.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8697_zps13e08d0b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8697_zps13e08d0b.jpg.html)

So then it was a case of fitting it all up. I think the first bolts you should so up are the ones above the centre diffuser part. It is just easier if nothing else is fixed so you can get your hands there. Some of the photos aren’t great because of the reflection from the actual cover. The best photo is last showing how it all works. I attached the centre of the plastic to the MR2 original fixing point using a bolt and a massive washer.  Once I had fitted it all up I painted all the metal brackets and screws/bolts black so it wasn’t so obvious through the grills.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8698_zps6ccd7c8b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8698_zps6ccd7c8b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8699_zps57f16ad1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8699_zps57f16ad1.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8700_zpsa90144b2.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8700_zpsa90144b2.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8701_zps9efe1c46.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8701_zps9efe1c46.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8702_zps82aea283.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8702_zps82aea283.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8703_zps885be456.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8703_zps885be456.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8705_zpsf92886c4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8705_zpsf92886c4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8706_zps589e3197.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8706_zps589e3197.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8704_zpse2c9c887.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8704_zpse2c9c887.jpg.html)

Finally, what do you think of my new tattoo? I got this doing this cover – I don’t recall the injury but I was up and down under the front bumper umpteen times today and must have scratched myself during it.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8733_zps3812d4fb.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8733_zps3812d4fb.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on June 21, 2014, 11:10:03 PM
get your scratch inked over, you will never ever forget these days, and in the future when on the beach and some one asks what does the tattoo signify, WOW what a reply 8)
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 21, 2014, 11:19:34 PM
Bonnet Badge

Here was another headache but it now sorted!

Here’s the story: The sunken part on the DNA 430 front bonnet is the size of the real badge. This is 57mm high. This is all well and good but a real badge is £120. I think this is a bit too steep for what it is. However, don’t use a sticker. It simply isn’t the same and won’t look as good.   I wasn’t sure what to do about the bonnet badge, but I got sent a free sticker one with my wing shields so thought I’d try it. It looked crap – it was too small for the sunken part and made the car look cheap. As soon as I fitted I checked eBay again and there were metal ones for £30. Damn. I thought I’d sleep on it. Told Dad the next day and he said for £30 it HAS to be the metal one. So after panicked phone-call to Dad while I was at work (I had fitted it the previous evening) he came round and removed the sticker with no fuss (or ripped paint). Phew!

Anyway my metal badge turned up and it was bigger than the sunken part. I had expected this from my previous research. However it looks tons better than the sticker so I went for it. It is large enough to cover the sunken part anyway. Upon reflection I would have just had the sunken part in the bonnet filled before painting so the cheaper metal badge could be fitted nice and flush. Anyway it has turned out fine and this is how I did it:

 Here is the £30 badge, complete with its prongs. I then made a card template to help guide me to drill holes in the bonnet

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8681_zpse64c5d4a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8681_zpse64c5d4a.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8683_zpsccb1cdc7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8683_zpsccb1cdc7.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8684_zps7caa6b8d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8684_zps7caa6b8d.jpg.html)

The DNA bonnet is thick but hollow, so you won’t be able to use the prongs like they are intended. In fact where the badge goes, the bonnet is really deep. So after the holes were drilled – just through the first skin on the bonnet, I trimmed the prongs so the badge could sit flush. Then I bonded the badge to the bonnet.  I chose to bond as opposed to tape because a) you have to deal with the sunken part and fill the gap and b) it allows you to adjust afterwards. It came out fine and passed the ‘wife’ test so that’s the main thing! LOL

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8707_zps673b1d14.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8707_zps673b1d14.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8708_zps14119faf.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8708_zps14119faf.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8709_zps1cabfb84.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8709_zps1cabfb84.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8710_zps999de6b7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8710_zps999de6b7.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8711_zps726a64b8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8711_zps726a64b8.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 21, 2014, 11:32:22 PM
Last update of the day.  Fitted up the driver’s door card long with the special screw in the door handle. Had to add the rivnuts as before but this was fairly trouble free in the end.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8712_zpscdea3fdb.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8712_zpscdea3fdb.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8713_zpsa2b68c8e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8713_zpsa2b68c8e.jpg.html)

So basically the interior was done. So I went and got the new mats I has ordered and fitted then. Gave it all a good hoover and clean and then took these photos. I am realty pleased how it looks!  The red mats make a hell of a difference and break up all the black that was there

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8714_zps24315e59.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8714_zps24315e59.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8715_zpscf6d8884.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8715_zpscf6d8884.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8716_zps07dcba74.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8716_zps07dcba74.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8717_zpse6ae9b62.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8717_zpse6ae9b62.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8719_zps8edbbdc9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8719_zps8edbbdc9.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8720_zpsd838267f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8720_zpsd838267f.jpg.html)


So finally as the car is pretty much done (apart from the roof) I have booked it in for the MOT on Tuesday (eek!) Fingers crossed. The garage it is going to,  regularly services a DNA built ex demo 360 so they know what to expect.  The below photos were for my insurance company so I can get an agreed value on the car now it is nearly done.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8722_zpsbc2a25e0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8722_zpsbc2a25e0.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8723_zpsd0d7c0aa.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8723_zpsd0d7c0aa.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8724_zpsc60a3cff.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8724_zpsc60a3cff.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8726_zps29ec09dc.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8726_zps29ec09dc.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8725_zpsaf58d7d7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8725_zpsaf58d7d7.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8727_zpsae3d2f29.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8727_zpsae3d2f29.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8728_zpsfd5614b5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8728_zpsfd5614b5.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8729_zps33c3a621.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8729_zps33c3a621.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8730_zps7633714d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8730_zps7633714d.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on June 21, 2014, 11:53:53 PM
I think cdrskull showed how to make a bracket for door handles in his 360 build
MADMAN
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on June 22, 2014, 10:07:35 AM
Looking stunning. Great build and a credit to you. Well done.
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on June 22, 2014, 10:44:42 AM
Fantastic progress mate....your storming through....

I have looked at my calendar and I only can fit in 5 more days working on the car before it goes to body shop!

Gulp!

Oh, as for the airbag light, I think this may depend on the MOT station, but I think the rule is that it MUST come on ( to confirm its working) and then go off ( to confirm airbags are good)....hence the reason for using the resistor....lets see what they say, you may get away with it....
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on June 22, 2014, 08:17:05 PM
 ;D she looks fantastic you've built a great car well done Paul  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 22, 2014, 09:33:26 PM
thanks for all the great comments guys. yes nearly there now. fingers crossed for Tuesday.  :)
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on June 22, 2014, 10:34:29 PM
you dont need to cross your fingers Paul, the tester will take one look at your car and see the work, passion and money that has gone into it he will pass it imediatly no worries
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 22, 2014, 10:47:55 PM
Cheers Steve, I do hope so! Will let you all know
Title: Re: Paul's 4thirty Build Diary
Post by: seriph on June 23, 2014, 11:15:11 AM
I think you'll need to keep some tissues handy for the tester  -  he'll take one look and lose it! That thing is gonna be one sweeeeeeeeeeeeet ride man - a total credit to you
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 24, 2014, 09:52:19 PM
A few more little jobs ticked off the list


Pininfarina script on sills

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8734_zps7612f244.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8734_zps7612f244.jpg.html)


D-Rubber in the channels where the roof t-brackets are:

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8742_zps12c0e722.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8742_zps12c0e722.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8743_zpsa88c3c17.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8743_zpsa88c3c17.jpg.html)


If you add a washer between the thumb screw and the t-bracket it will tighten up and hold the bracket much more firmly

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8744_zpsace91438.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8744_zpsace91438.jpg.html)


Added some foam tape to the underside of the dummy engine as when the rear deck closes it hits the car body and makes a noise – this now softens the blow

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8745_zps41991abb.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8745_zps41991abb.jpg.html)


Some pictures before I put her away on Sunday

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8739_zps64f2740d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8739_zps64f2740d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8740_zps94c37311.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8740_zps94c37311.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8741_zps11f77bb5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8741_zps11f77bb5.jpg.html)


Here’s me having a kip under the car the other day whilst dong the front bumper under cover

(http://i65.photobucket.com/albums/h229/pjlucas2/6e2ba82f-3b1d-464f-84c4-89b051bd4280_zps5516ef14.jpg) (http://s65.photobucket.com/user/pjlucas2/media/6e2ba82f-3b1d-464f-84c4-89b051bd4280_zps5516ef14.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 24, 2014, 10:07:58 PM
So today was MOT day! I took a half day from work and rushed back from London for the 2.30pm booking. It was a bit nerve wracking to say the least, but I am happy to report: IT PASSED!!! Hooray!!!   ;D ;D ;D

The only advisory was the handbrake was travelling a bit too far, but it still came up as a pass on the computer so happy days! The passenger headlight alignment was spot on and the driver’s one needed only minimal adjustment. I also had the tracking looked at and that needed just a slight tweak. There were no issues with the 3rd brake light flasher, or the fact that the airbag light was blanked out and didn’t come on.

Here are some pictures from the test centre

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8746_zpseed658ac.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8746_zpseed658ac.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8747_zps91883bf9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8747_zps91883bf9.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8748_zps992258c4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8748_zps992258c4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8749_zps899feaa8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8749_zps899feaa8.jpg.html)


Then it was a case of driving her back. I took the long way home! LOL

When I got home I had about an hour left before it was due to rain, so I added back the driver’s front arch liners.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8750_zpsf6d4b5ff.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8750_zpsf6d4b5ff.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8751_zps201da2e5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8751_zps201da2e5.jpg.html)


Here you can see how the lower arch liner lip, bolts (circles) to the bracket I had added to the undercover via rivnuts (arrowed). This is all nicely firm in place.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8752_zps346da964.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8752_zps346da964.jpg.html)


So what is left to do?  Main things are: door weather seals, passenger front arch liner and of course the roof! The bonnet also needs the bump stops adjusting as out on the open road it was moving too much and rattling. These things are a trial and error thing I suppose!!  :)
Title: Re: Paul's 4thirty Build Diary
Post by: cheets on June 25, 2014, 04:46:08 PM
Looking good bud  8) defiantly a bit jealous but i will back at it soon  just 7 weeks
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on June 25, 2014, 05:30:45 PM
 :) wow so pleased for you Paul that pic of you under the car reminded me of the film christine thought she had turned on you looks like she about to eat you  ;D  bet the garage were well impressed with your handy work you and dad have done a cracking job  :o
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 29, 2014, 08:50:51 PM

Time for an update…

Added the outer door weather strips. I used no-more nails tape and stuck the door strip to the vertical part of the door, all the way along. I trimmed the strip slightly so it would fit around the wing mirror area as well.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8753_zpsf0305a7b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8753_zpsf0305a7b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8754_zpsd68bb943.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8754_zpsd68bb943.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8755_zps0dee1be8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8755_zps0dee1be8.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8756_zps704cdda2.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8756_zps704cdda2.jpg.html)


Arrow show how it is all stuck to the back of the mirror triangle

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8757_zps21680882.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8757_zps21680882.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8760_zpsd7e527fa.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8760_zpsd7e527fa.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8761_zps308dc025.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8761_zps308dc025.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8762_zps2ab82d63.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8762_zps2ab82d63.jpg.html)


I added this eye bolt to the metal roll bar carrier bracket. This is going to form part of the rear-deck safety strap. I will post more details when I have the fixings and strap.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8758_zps30c98036.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8758_zps30c98036.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8759_zps7c8d8243.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8759_zps7c8d8243.jpg.html)


 When I drove the car for the 1st time to the MOT centre I noticed the door mirrors vibrate a little. I thought maybe something could be done to reduce this. I had a look as saw there is a bolt at the top of the window glide rail, which I undid and then added a standard mending plate and then bonded to the rear of the door mirror triangle part. This seems to have helped a bit having driven the car today.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8763_zps49ba14d9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8763_zps49ba14d9.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8764_zps62d107e7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8764_zps62d107e7.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8765_zps965d8ab1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8765_zps965d8ab1.jpg.html)


I’ve added back the passenger front arch liners and also added this Pininfarina script to the dashboard

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8767_zpsab746469.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8767_zpsab746469.jpg.html)


Some other little tips:

I noticed that arrowed here below this is a very sharp bare metal edge- part of the original MR2, so I have put some trim rubber on it in case the new roof gets caught on it

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8822_zps62cc4994.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8822_zps62cc4994.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8823_zpsdb75d088.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8823_zpsdb75d088.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8824_zps28d932c0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8824_zps28d932c0.jpg.html)


I finally sorted my z-flaps

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8828_zps7f92cdf4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8828_zps7f92cdf4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8829_zpsa5388336.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8829_zpsa5388336.jpg.html)


Added foam tape to the underside of the pods where they go on the top of the z-flaps

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8837_zps68a6fce9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8837_zps68a6fce9.jpg.html)


The area below looked untidy where the DNA kits bonds to the MR2 body so I added some d-rubber to hide the join

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8838_zpse82c159f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8838_zpse82c159f.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8840_zps17512d12.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8840_zps17512d12.jpg.html)


Added a trim rubber here because when the pods are folded underneath and locked and the deck is closed, IF they were to come lose and flip upwards they’d hit this bare metal. So adding a rubber here would hopefully stop them scratching if this were to ever happen.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8841_zpscb20a28c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8841_zpscb20a28c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8842_zps7b76dc17.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8842_zps7b76dc17.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8843_zps34c534d2.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8843_zps34c534d2.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8844_zps40ea31f3.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8844_zps40ea31f3.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 29, 2014, 09:17:10 PM
ROOF FITTING

So the last big job to do was the roof! I thought about having this done by a trimmer, but locally no one had done one before. Dad has some experience with roofs anyway and seeing as we have built the rest of the car, we thought we’d give it a go  ;D There is only really one build thread that has any detail on this which is Manta’s so big thanks to him for the photos he put up. There are paper instructions flying around which help, but a lot of it all becomes clear when you actually have the car in front of you. I’ve taken tons of photos so this should help future builders a bit. Have lots of bags ready to put all the various bits in and label them all up. Also, all of the material I removed I’ve kept in a bin bag, just in case. It can be chucked when you definitely know it is not needed. Here goes…

Here are the pieces in the kit:

Main roof

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8807_zps7036019e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8807_zps7036019e.jpg.html)

The rear part have pockets on the inside to slide the plastic base parts into that then latch onto the t-brackets that pop up thru the rear deck. DNA mark where to cut out the canvas to allow for the bracket parts to poke through.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8808_zps63b853c7.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8808_zps63b853c7.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8809_zps6b41f93a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8809_zps6b41f93a.jpg.html)


Here are the base parts. Even though they slide in the pockets eventually, the initial fit up you’ll be trying them without the canvas roof. The end are bar fibre glass, so they are rough and would scratch your paint work, so cover them in tape to soften them up.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8810_zps1bd0cebb.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8810_zps1bd0cebb.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8811_zpsa51a0b06.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8811_zpsa51a0b06.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8812_zps92f3ce56.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8812_zps92f3ce56.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8813_zps730e270b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8813_zps730e270b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8814_zpsa24618b4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8814_zpsa24618b4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8849_zps953e3154.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8849_zps953e3154.jpg.html)


This is the section that goes down inside the car, just behind the back of the doors. You need to pop-rivet a MR2 bracket to this part when then is bolted to the MR2 frame. The area where to rivet is marked.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8815_zpsbb600e15.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8815_zpsbb600e15.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8816_zps3b0499d2.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8816_zps3b0499d2.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8817_zps3d6d4386.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8817_zps3d6d4386.jpg.html)


This is the interior headlining

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8818_zps024c28d1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8818_zps024c28d1.jpg.html)


This part helps pull the rear screen down to the car body and the strap feed through the roll bar carrier cover and secure inside the storage bins.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8819_zps55e56cf4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8819_zps55e56cf4.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 29, 2014, 09:48:51 PM
Stripping the old roof off the frame:

Here we have the original roof folded back in place. You need to start by completely stripping all the old material off the frame. You also need the carpeted piece that goes beneath the folded roof removed for this.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8769_zps0b4e0930.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8769_zps0b4e0930.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8770_zps9977577d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8770_zps9977577d.jpg.html)


Remove this metal as per the paper instructions

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8771_zps7646d066.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8771_zps7646d066.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8772_zpsce5fdc11.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8772_zpsce5fdc11.jpg.html)


This is the front header rail. You need to undo the screws and remove this metal and the end rubber parts and keep for later

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8773_zps07cf9641.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8773_zps07cf9641.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8775_zps011cc542.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8775_zps011cc542.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8776_zps6d09fc11.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8776_zps6d09fc11.jpg.html)


The front part of the window side rubbers just pull off once you have released the poppers. They reveal this metal below secure by 3 screws at the side…

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8778_zpsd413d678.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8778_zpsd413d678.jpg.html)

And one screw at the front!!

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8779_zpsa23be311.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8779_zpsa23be311.jpg.html)


The original roof will also be secured via these 3 screws that are under that silver strip part!!

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8780_zps8bda1ad8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8780_zps8bda1ad8.jpg.html)


This is the cable and spring setup the paper instruction talk about. This is at the top of the roof. Undo the screw and carefully remove the cable from under the clip


(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8786_zps624879bb.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8786_zps624879bb.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8787_zps7e27a9f9.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8787_zps7e27a9f9.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8788_zps91262662.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8788_zps91262662.jpg.html)



This cable and spring set up goes between the sides of the MR2 roof. I have removed and kept just in case, but I don’t think it is needed.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8782_zpsb180be09.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8782_zpsb180be09.jpg.html)

Removing the rear side window rubbers et al

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8783_zps686d537d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8783_zps686d537d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8784_zpsf50ef505.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8784_zpsf50ef505.jpg.html)


They are secured with poppers as well – here is the one at the bottom. Hard to see

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8785_zpsb01e59ef.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8785_zpsb01e59ef.jpg.html)


The paper instructions talk about the bracket that holds a cable that is pop-riveted onto the MR2 roof that you need to drill off. It is located just behind the tops of the rear of the doors. It is very hard to see unless you remove all the window rubbers etc.. The arrow below shows one of the rivets you need to drill out. Once you drill it off the rivets to remove the bracket from the roof frame by undoing a 10mm nut

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8790_zps0c157485.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8790_zps0c157485.jpg.html)


To do the actually drilling off, fold the roof back inside the car and you’ll have better access – see below

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8795_zps96be19c4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8795_zps96be19c4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8797_zpsa7064ac4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8797_zpsa7064ac4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8791_zpscc993bd8.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8791_zpscc993bd8.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8793_zpsb9fbf04e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8793_zpsb9fbf04e.jpg.html)

Once you have drilled off the rivets and removed the cable from the old roof, this is what you have left

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8799_zpsaf256378.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8799_zpsaf256378.jpg.html)


Remove the rectangular bracket off the frame as per the paper instructions – it is bolted with a wire into the car body further down

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8800_zps3c34fc3c.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8800_zps3c34fc3c.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8801_zps57275af2.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8801_zps57275af2.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8803_zpsc568e3ad.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8803_zpsc568e3ad.jpg.html)


This is the cable and bracket you have just removed

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8804_zps2ea9efbe.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8804_zps2ea9efbe.jpg.html)


Side rubbers

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8820_zpsb2cb3435.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8820_zpsb2cb3435.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8821_zpsbedd680d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8821_zpsbedd680d.jpg.html)


All done

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8806_zps08dadbff.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8806_zps08dadbff.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 29, 2014, 09:58:59 PM
When I got the car out today I finished off removing the old roof on the passenger side and gave it all a good clean up

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8825_zps1cd4fb19.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8825_zps1cd4fb19.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8826_zpsf20935ea.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8826_zpsf20935ea.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8827_zps20a0e75b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8827_zps20a0e75b.jpg.html)


Added the rear plastic base parts

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8830_zps471c1982.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8830_zps471c1982.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8831_zpse8a95ee5.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8831_zpse8a95ee5.jpg.html)

It had been raining on and off and then it started to get heavier, so thought we’d get the car inside and we tried out the actual roof just to see how things went  ;D I definitely recommend doing this from the start so you can really get a sense of how things are meant to be. On the rear bar, we added the foam tube as per the paper instructions just to see how it would sit.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8832_zpsf6ea04bf.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8832_zpsf6ea04bf.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8833_zps7a0992dd.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8833_zps7a0992dd.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on June 29, 2014, 10:05:54 PM
***QUESTION***

So I finally end on a question for you guys....am I correct in thinking for the rear screen we bond this black rectangular piece to the flap I have highlighted below and then this piece sits on top of the car with the straps going down between the gap in the rear deck/rollbar cover and through the slots I have cut out in the roll bar cover? It must surely need to be bonded to this flap - it can't just be freely loose each time?

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8819_zps55e56cf4.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8819_zps55e56cf4.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8846_zps9eecc812.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8846_zps9eecc812.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8847_zpscaf40f99.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8847_zpscaf40f99.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8848_zps97c4a6ab.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8848_zps97c4a6ab.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8834_zps03dfe471.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8834_zps03dfe471.jpg.html)

Title: Re: Paul's 4thirty Build Diary
Post by: V8 KLR on June 30, 2014, 06:25:33 PM
Paul here are some pics of how I did mine. The hood loops around the rear of the fibreglass section and wraps underneath it see photo. I cut a strip of plastic from the wheel arch material which I had spare when I redid them as this was strong but flexible. I used this to fix the hood to the fibreglass piece. It was originally riveted on without the strip I added but I used some small nut and screws instead and the strip added more support. I then trimmed the whole thing in red leather as this hid the counter sunk screw heads on the top surface of the fibreglass piece and to stop them showing through I added and a thin layer of foam. On the underside to stop the screws showing I added a long piece of dense foam. This protected the bodywork but also filled a small gap between the hood and the body. This I held in place with strong double sided tape. Hope that helps if not I can zipp round and you can have a look.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 01, 2014, 11:44:54 PM
Thanks for all that info Andy. I've attached it tonight and works fine thanks. Will update the diary at a later date.
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on July 02, 2014, 10:39:11 AM
Very detailed.  It's at this point I'm glad DNA built mine.  Mechanical stuff OK.  Trim is a bit of an art beyond me, and I did part of my apprenticeship in trim department.
Some kit cars look a bit tat.  The level of work shown here is remarkable.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 02, 2014, 08:32:16 PM
Here is more information on the safety strap idea I had.

Here is the eye bolt I installed into the metal roll bar carrier

(http://i65.photobucket.com/albums/h229/pjlucas2/photo1_zpsc8aee08b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/photo1_zpsc8aee08b.jpg.html)


I got sent this heavy duty bike chain by mistake when I bought a work lamp off eBay. I spoke to the vendor who said he’d send the right product instead, and said I could keep the chain. These retail at £15  - so that was a result. A chain is best to use here because it collapses into a space because of the links. I thought about using a safety wire but that would be more rigid and get in the way more when the deck was closed. The chain is all covered with material anyhow

(http://i65.photobucket.com/albums/h229/pjlucas2/photo2_zpsd1be3471.jpg) (http://s65.photobucket.com/user/pjlucas2/media/photo2_zpsd1be3471.jpg.html)


I added a Climbing Carabiner clip to the end

(http://i65.photobucket.com/albums/h229/pjlucas2/photo3_zps3cd649f6.jpg) (http://s65.photobucket.com/user/pjlucas2/media/photo3_zps3cd649f6.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/photo4_zps80a67afe.jpg) (http://s65.photobucket.com/user/pjlucas2/media/photo4_zps80a67afe.jpg.html)


…and then I connected it up. So when the deck opens, the chain is long enough for me to get to the clip to undo it.

(http://i65.photobucket.com/albums/h229/pjlucas2/photo5_zps6c3a2f95.jpg) (http://s65.photobucket.com/user/pjlucas2/media/photo5_zps6c3a2f95.jpg.html)


Hopefully I’d never have to call upon its services but I feel safer in the knowledge it is there. It should stop the worst happening and give me chance to stop the car in time. 
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 02, 2014, 09:32:11 PM
So next I tackled the rear screen and the rectangular screen plate. Thanks again to Andy for his detailed photos.

The first job was to ensure I attached the screen plate correctly so the straps were in the right position. On the car I masked up exactly where the slots were in the roll bar carrier and that attached the roof again and masked on the rear screen where the slots would be in relation to the rear screen

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8863_zps3529acb6.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8863_zps3529acb6.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8864_zps77774de0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8864_zps77774de0.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8865_zps6157bb61.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8865_zps6157bb61.jpg.html)

Next I drilled holes in the rear part of the screen plate. My plan was to use screw bolts and instead of washers on the inside, use mending plates as they would effectively trap more of the screen flap. I measured accordingly the holes so they matched the holes on the mending plates and, on the outer plates I added a slight bend to follow the contours of the screen plate. The rear screen has a slight curve on the outside edges of the screen and the screen plate also has this.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8866_zps9a966f34.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8866_zps9a966f34.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8867_zpse2652b95.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8867_zpse2652b95.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8868_zpsf8650a77.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8868_zpsf8650a77.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8869_zps9cc67b50.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8869_zps9cc67b50.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8870_zps5bb9eb9f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8870_zps5bb9eb9f.jpg.html)

Here you can see the screw bolt heads, but when in situ you can’t see them as the lower part of the hood beneath the window hides them

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8871_zpse0e48dbc.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8871_zpse0e48dbc.jpg.html)

On the reverse side I covered everything in gaffer gap to keep all in check and also to cover up any metal that could scratch the hood.  I also added a strip of foam tape as well.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8872_zps1ca2bf10.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8872_zps1ca2bf10.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8873_zpsc4c7eec2.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8873_zpsc4c7eec2.jpg.html)

I placed the roof back on car and all was well. The window pulled down nicely with the straps.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 02, 2014, 09:42:08 PM
Some of the other jobs I got done today were adding a steel plate to the passenger wing mirror like I had done on the driver’s one. The vibration on the driver’s side has been reduced a little by this plate so thought I might as well do the passenger side as well. I also cut a template out for the mirror backing plate on the driver’s side.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8874_zpsb7b64f1f.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8874_zpsb7b64f1f.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8875_zps45c6489e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8875_zps45c6489e.jpg.html)


Added the Ferrari sill plates

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8876_zps5cc9c926.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8876_zps5cc9c926.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8877_zps4c9f6b87.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8877_zps4c9f6b87.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8878_zps1b299922.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8878_zps1b299922.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8879_zpscb817d1d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8879_zpscb817d1d.jpg.html)


…and the wing shields. I stuck the shields on first with a blob of blue-tak to get the position right and then added masking tape and drew lines to the 4 points on the shield. That way I had a guide when I was ready to stick them properly and joined the line up with the points of the shields. They really do finish off the car. I love em!

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8892_zps4d86dd43.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8892_zps4d86dd43.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8893_zps18e8cf1e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8893_zps18e8cf1e.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8894_zpsccee8d9a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8894_zpsccee8d9a.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 02, 2014, 10:13:38 PM
With the roof on the car, I needed to set the distance of the rear bar. This bar has 2 springs on it on the MR2 roof, but you need to remove these. The bar has to come back and supports the roof just above the rear window. If you look at other diaries you’ll see that rear bar gets covered in foam padding. When fitting my roof I found that with this extra padding meant the rear window was pulled up too much thus creating a gap. So I decided to do away with it.

Once I had decided on the exact position of the rear bar, I needed a way of making it stay where it was before we took the roof off again. I got some gaffer tape and basically taped securely between the rear and middle bar (see photos). I taped in such a way that when the bar was pulled back as far as it could go it was in the right position.  I did this on both sides

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8880_zpsd161bc19.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8880_zpsd161bc19.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8881_zpsd10926f1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8881_zpsd10926f1.jpg.html)


Next on the straps that connect to the rear feet part that connects to the deck I position it accordingly and marked it on the middle bar. As a guide it is to the outside of the roof seam

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8882_zpsde922919.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8882_zpsde922919.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8883_zps0d30235b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8883_zps0d30235b.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8884_zps8455d236.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8884_zps8455d236.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8885_zpsc8839f07.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8885_zpsc8839f07.jpg.html)


Once I was happy we removed the roof and the attached the 2 straps to the bars via large headed rivets. Do the middle bar first and then the rear bar. I pulled the strap back on itself and secured in-between the 2 bars as well with 2 rivets for a neater finish.  The circles are the holes I drilled and the arrows are some MR2 fixing points that are on the bars already. You'll need to remove these - just drill out the rivets and cover in tape - otherwise they’ll get in the way of the headlining.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8886_zpscadb9358.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8886_zpscadb9358.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8887_zps5402abde.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8887_zps5402abde.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8888_zpsb9c06649.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8888_zpsb9c06649.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8889_zps5e5d52b0.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8889_zps5e5d52b0.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8890_zpsd3696469.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8890_zpsd3696469.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8891_zpsb0301735.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8891_zpsb0301735.jpg.html)


Final job of the day was to make a start on the headlining. We found the best way to approach this is to start at the front and work backwards. We stuck the headlining at the front on the top of the frame. There was a lot of overhang which is good as it means you can release the frame at the front and tuck it underneath and then lock the roof off. It acts like a clamp all the way along. It will be trimmed later. You can then pull the headlining backwards and glue around the front bar. We covered the front bar in glue and then wrapped the lining round the bar as you pull it backwards tightly. We used one of the foam tubes to act like a clamp to hold it all in place which will be removed once dry. I wouldn’t try to do the next bars until this one has dried off as you’ll disturb things. So that is for another day.

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8895_zps7fd2dfcf.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8895_zps7fd2dfcf.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8896_zps294466fd.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8896_zps294466fd.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8897_zps63450f83.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8897_zps63450f83.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8898_zpsd88e94da.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8898_zpsd88e94da.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8899_zpsa7550ae1.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8899_zpsa7550ae1.jpg.html)

Fist part is nice and tight

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8900_zps8bcfea5b.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8900_zps8bcfea5b.jpg.html)


A few full shots before putting her away

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8901_zps6a8d6384.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8901_zps6a8d6384.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8902_zps358c80f3.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8902_zps358c80f3.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8903_zps17407775.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8903_zps17407775.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8904_zps7f3f7e2d.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8904_zps7f3f7e2d.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8905_zps6350d753.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8905_zps6350d753.jpg.html)


Finally a couple of hours later I went in the garage and look who I found asleep in the car!!! Looks like I’ve got my own Furrari!!!!

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8906_zps35efdade.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8906_zps35efdade.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on July 03, 2014, 08:10:34 AM
Paul.  Ref your Furrari.  That's where we got ours.  If you get the fur on the roof lining use masking tape to remove it.  From one Furrari to another.

M
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on July 03, 2014, 08:32:41 AM
Paul,
You have created a great car mate. The detail you have put into the car and your build thread is a credit to you and a great example for other members and owners to follow and learn from.
Looking forward to seeing it.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 05, 2014, 08:50:46 AM
thanks for the great comments guys - just one final push and she'll be finished. hope to make more progress on the roof this weekend.  :)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 05, 2014, 09:05:37 AM
Just a quick update while I am waiting for the kettle to boil…

If you have fitted secondary cables to your rear deck, you may find that the spring in the catch is not strong enough to spring back once you have opened the rear deck because of the 2 cables each side. You can move them back by hand each time the deck is opened but this is a bit of a pain.

You want the catch to move back in the direction of the arrow below. So I planned to fit a spring one a bracket to do the job. Hole drilled at the circle in preparation for the bracket

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8907_zps0d76de33.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8907_zps0d76de33.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8908_zps4ef4774e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8908_zps4ef4774e.jpg.html)

Here it is all fitted up. You want the spring to be under slight tension so it can pull itself back once you open the catch

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8909_zps3d9ec56e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8909_zps3d9ec56e.jpg.html)

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8910_zps7f593a8a.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8910_zps7f593a8a.jpg.html)

Also trimmed the headlining at the front

(http://i65.photobucket.com/albums/h229/pjlucas2/IMG_8911_zpsfcfbfd9e.jpg) (http://s65.photobucket.com/user/pjlucas2/media/IMG_8911_zpsfcfbfd9e.jpg.html)

Better go... the kettles boiled!!!
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on July 05, 2014, 04:14:01 PM
 :) enjoy your drink you've earnt one great build
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 10, 2014, 11:22:19 AM
OK guys - so I've been working away in the evenings and I am pleased to say the majority of the roof is done. I need to look at securing the rear window straps but the hood and headling is all complete and fitted. I will update the process pictures in due course, but here is a sneak preview of the completed roof.



Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on July 10, 2014, 11:35:46 AM
that looks great! well done mate!
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 10, 2014, 09:55:35 PM
So back to the roof fitting - After setting the rear bar with the rivets I wanted to check all was well with the roof over it so added it back. All was well.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8913_zpsbd06bf68.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8913_zpsbd06bf68.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8914_zps15cc6e55.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8914_zps15cc6e55.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8915_zps3ddd1e8e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8915_zps3ddd1e8e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8916_zps3b755482.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8916_zps3b755482.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8917_zps16eb7b6d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8917_zps16eb7b6d.jpg.html)


Next was time to rivet the cable bracket to the lower parts of the hood that go to the rear of the doors. I made holes in the marked areas on the hood, and also enlarged the holes on the bracket to take the bigger rivets I had. Sorry -  I didn’t get a photo of the actual bracket riveted to the hood!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8918_zpsa3879d33.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8918_zpsa3879d33.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8919_zpsbd207fce.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8919_zpsbd207fce.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8920_zps89dd3765.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8920_zps89dd3765.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8921_zps7069053b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8921_zps7069053b.jpg.html)


Added the hood back and attached the bracket to the frame of the car using the nut. The area I am talking about is marked in the arrow below

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8924_zpsd1dda578.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8924_zpsd1dda578.jpg.html)


Next was time to mark up the curved rear part of the side windows where the cable runs. To do this you need to have the window edging trim attached to the roof frame on the car to help you mark it accurately. I know I had removed it all previously but I added it back. (You don’t need to add the bits back on the front part of the frame as the hood here is just stuck underneath to the frame near the end of the job.)

With the trim in place you’ll be able to feel the top edge of it through the hood, and you can use it as a template to draw a chalk line. You basically need to fold the hood flap under itself to create a channel for the cable to run in. It will be obviously once you get there, but the art is getting that fold just right so that the canvas comes done just enough to tuck under the lip of the window rubber edging part. So I marked my line first all the way around, just so I knew where things were. The fold I would make would actually be lower than this line. You need to do all of this with the hood on the car and everything in place as if the roof was fitted properly to take any slack out of the canvas. So ensure the rear wing bits are fitted properly and it is locked off at the front on the header rail.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8925_zps735fc711.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8925_zps735fc711.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8926_zps8f823799.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8926_zps8f823799.jpg.html)


After doing both sides I took the hood back off the car and worked out where the fold should be. I did this and drew a second line lower down.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8927_zps5606ab35.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8927_zps5606ab35.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8928_zpsd23c2514.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8928_zpsd23c2514.jpg.html)

It was the second line where I made the cuts to, which then allowed me to fold the canvas underneath to create the channel.  ***REMEMBER*** take the cautious approach. IF you make the fold too high up the roof it won’t reach and tuck nicely under the groove in the window edging bits and it would be game over. Better to take the trial and error approach and err on the side of caution. If you make the fold too low, then you can always re-do it. I used evo-stick to do all the sticking and on the driver’s side I had to do redo it twice as there was too much slack in places. 

After making the cuts, we gradually stuck the flaps, WITH THE CABLE INSIDE. If you try to do it with the cable outside, you’ll have a bit of a job getting the cable back in afterwards. Use clothes pegs to aid the bonding.

Also you don't make the channel all the way along. It should stop near the top where the rear edging trim ends and the cable should poke out. Again it will make sense when it is in front of you. This point is also on the DNA instructions.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8929_zps0b2251d3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8929_zps0b2251d3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8930_zps8e53f305.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8930_zps8e53f305.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8931_zpse388ddc5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8931_zpse388ddc5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8932_zps771dc24b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8932_zps771dc24b.jpg.html)


continued.....
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 11, 2014, 09:37:49 AM
Next I finished off the headlining. With this, I worked from front to back. Again I used evo-stick. The headlining will need trimming in places on the middle and rear bars to avoid the straps. I didn't need to use any of the foam tubes as padding on the rear bar. The foam tubes in the photos are just there to help hold the lining while the glue sets. Once done I also covered certain areas with black gaffer tape to help secure things further and to neaten things up.


(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8933_zps3f2ed66e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8933_zps3f2ed66e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8934_zps66c55898.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8934_zps66c55898.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8935_zps04359167.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8935_zps04359167.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8936_zps0c03f404.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8936_zps0c03f404.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8939_zps827aa459.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8939_zps827aa459.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8940_zps0a3d9512.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8940_zps0a3d9512.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8941_zpsb80290fa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8941_zpsb80290fa.jpg.html)


Once the glue had set on the window channel folds I tried the roof again with everything connected, bolted and locked down on the roof as if it were finished.  The passenger side was perfect but the driver’s side needed taking in a bit more in places. This was simply a case of unpicking part of the glued canvas and making the channel fold further up the roof.  As mentioned previously I had to do this twice on driver’s side to take all the slack out.


(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8949_zps7ad8390a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8949_zps7ad8390a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8956_zpsfd7db1d8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8956_zpsfd7db1d8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8957_zps1651a240.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8957_zps1651a240.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8958_zpsbc5b1b50.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8958_zpsbc5b1b50.jpg.html)



Once happy with this part I moved to the front section of the roof. The front side bits of the canvas are just glued to the frame like the MR2 one. There are 3 tiny screws you can use as well. BE CAREFUL if making holes in the canvas for these screws if doing with roof on the car. You don't want to slip and end up putting a hole through the main canvas! I had to trim the canvas a bit as it had a lot of overhang, but then it was glued and screwed. You can even use the edging trim piece as well and put this on top to act as a clamp while the glue sets. Just make sure the piece is clean etc as this goes over the top edge of the canvas. Just used the 3 side screws for this piece - not the front one as this is not really needed at this point plus you need to tidy the canvas up at the front still. 

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8960_zps99fa2c27.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8960_zps99fa2c27.jpg.html)


Finally I did the front header rail gluing. Again I trimmed back some of the material and put plenty of glue in place and folded it underneath itself and used pegs to help hold it all along. Once the glue had taken hold I added back the metal strip - you should be able to do this still with the pegs in place. The corner bits were just folded and stuck like you would do a corner of a box when wrapping up a present. However I cut a little square hole each side to allow for the screw bolt that secures the front window edging trim to pass through before sticking down. This screw has a flat end so piercing the canvas by screwing it would be difficult. 


(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8962_zps19fb393b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8962_zps19fb393b.jpg.html)



Finally, I added back the window rubbers. The best way is to tuck the lower parts in the slots and then push the top in via a little flat screwdriver to force the edge under the metal lip so it catches. The front edge rubbers are secured at the front with a screw and a push popper. The screw is a pointed one so you should be ok piercing a small hole and then screwing it in. Once done,  make a further hole for the push popper and force the popper.  All done.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8963_zps2c267162.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8963_zps2c267162.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8965_zps0aea703b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8965_zps0aea703b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8966_zps196b74f5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8966_zps196b74f5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8967_zps61e0395c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8967_zps61e0395c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8968_zpsd49056a1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8968_zpsd49056a1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8969_zps49b3d3db.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8969_zps49b3d3db.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8970_zpse28d8cec.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8970_zpse28d8cec.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8971_zps4e642e07.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8971_zps4e642e07.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8972_zps95b5eb3d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8972_zps95b5eb3d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8961_zpsfe0e24bd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8961_zpsfe0e24bd.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8973_zps0b0c48a9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8973_zps0b0c48a9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8974_zpsb7bed26e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8974_zpsb7bed26e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8975_zps0e2da60b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8975_zps0e2da60b.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on July 12, 2014, 11:47:11 AM
 :) wow fantastic job on the roof will try your lining job on my tt roadster a job I can afford to do yippee well done Paul and dad you really have built a beauty >:(
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 13, 2014, 09:00:13 PM

The final bits I to do on the roof were the rear window straps. Throughout the fitting up of the roof previously, the window straps had unfortunately ruined my d-rubber that was installed on the rear deck.  I thought about re-doing the whole rubber, but the issue is the fact the gap is very tight there and the pulling of the strap is always going to rub on the d-rubber if it is there. So I cut out the dodgy bits and was left with the below. I decided to put some foam tape I there for now to hide the fact there is a gap and protect the paint, and I will see how it goes. It doesn’t look terrible with the roof down and I am sure most people wouldn’t even notice LOL!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8976_zpsdb25df42.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8976_zpsdb25df42.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8977_zps911603d0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8977_zps911603d0.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8978_zps709f0bba.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8978_zps709f0bba.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8979_zpsb289d098.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8979_zpsb289d098.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8997_zpsb2eb9101.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8997_zpsb2eb9101.jpg.html)


Here you can see the straps going through the slots I had made previously

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8986_zpsdb720051.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8986_zpsdb720051.jpg.html)

I wanted to see if it was possible to have the straps being secured inside the rear glove boxes not on the outside. As luck would have it, the straps when it feeds down in the glove box, is exactly over the middle bolt that is used to secure the doors.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8987_zps3c9a8e81.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8987_zps3c9a8e81.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8988_zps10e6c202.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8988_zps10e6c202.jpg.html)

I had bought some of these luggage straps and the plan was to use the catches on these to secure the other straps

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8989_zps3e0e3dfc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8989_zps3e0e3dfc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8990_zps9256f5fa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8990_zps9256f5fa.jpg.html)

I made the strap about 9 inches long and then made a hole in the material for the glove box bolt to go through. A couple of washers and bolted it in place. It works perfectly.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8991_zps7209abfe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8991_zps7209abfe.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8993_zps367c4ee2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8993_zps367c4ee2.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8994_zps8999d1cc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8994_zps8999d1cc.jpg.html)

With the door shut you can just make out the strap

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8995_zpsff71c661.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8995_zpsff71c661.jpg.html)

The view from inside

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8996_zpsc2883fbc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8996_zpsc2883fbc.jpg.html)


Both done

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9005_zps16f17bd4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9005_zps16f17bd4.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 13, 2014, 09:17:39 PM
Another job on the snag list, was the passenger b-pillar top rubber trim. When the roof came up the rubber was sitting too high and the roof rubber edge piece would not clear it and sit properly.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8980_zpsb53e279d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8980_zpsb53e279d.jpg.html)

I removed it and worked out it was this part of the actual kit that was protruding too much thus not allowing the rubber to sit properly. So I carefully cut it off and then it now clears and sits nicely.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8981_zps019175c8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8981_zps019175c8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8983_zps68e57362.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8983_zps68e57362.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8985_zps01fca2b4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8985_zps01fca2b4.jpg.html)


Another snag was my steering wheel wasn’t perfectly straight when driving, plus there was some rattles coming from it. So I took it all apart, straighten it, and then put some u-channel rubber along these edges for the silver plate part to butt up against and be really snug. Put it all back and much better. You can hardly see the u-channel rubber either and it all feels much more solid now.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8999_zpse83ba35d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8999_zpse83ba35d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9000_zpse0c3fc0e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9000_zpse0c3fc0e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9001_zpse3df2252.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9001_zpse3df2252.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9002_zps6535a764.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9002_zps6535a764.jpg.html)


I also pimped up my floor mats. I bought some cloth badges and glued them on. I really like this mod. Very simple but very effective.  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9003_zps56dde113.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9003_zps56dde113.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9004_zpse74b8e27.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9004_zpse74b8e27.jpg.html)


Here are some more shots of the completed roof

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9008_zpsb6f01020.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9008_zpsb6f01020.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9009_zps9e375cec.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9009_zps9e375cec.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9010_zpse65ee53a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9010_zpse65ee53a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9011_zps053ffbcb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9011_zps053ffbcb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9006_zps5bf36ce7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9006_zps5bf36ce7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9007_zps0d0233ae.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9007_zps0d0233ae.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 13, 2014, 09:50:25 PM
Well people, I know kit-cars are never truly finished but for now the car is pretty much done. There are a couple of small things left to do, but all the hard work is complete. It’s a bit of an end of an era as well. Dad bought a new house this week so he will soon leave the home where the car was ‘born’ never to return. 

I’d just like to say a few thank yous. Firstly MASSIVE thanks to my Dad - I couldn’t have done this without him and I am eternally grateful to him for helping me and sticking by me throughout it all. I know it has been tough and he ended up doing much less of the actual building because of his accident, but he was always there for me and his advice was top-class when I came up against a problem. It’s been great spending time together as well and we’ve had some great laughs along the way!

Second thank you goes to my long suffering wife, Jules. She has been great throughout it all and I truly love her dearly.  It has been tough for her while I spent endless hours away at Dad’s and in the garage and she’s had to put up with a lot but she has always been supportive of my project as she knows it has been something I have always wanted to do. I promise I’ll make it up to you babe!!! LOL..

And finally a big thank you to DNA and everyone on this forum. You are all a cracking bunch of guys who after this past year I can really call my true friends. I apologise for the endless messages/texts/emails to some of you, (you know who you are), asking for help and advice on various things but it has all been a big help to me and I have really appreciated it. I will return the favour one day when I hopefully meet you at some shows.  Your help and advice has been spot on and the continued comments of encourage really help and are a great motivation. 

I feel a little sad that the build is basically done as it has been such a big part of my life this past year, but this isn’t really the end - it is the start ……. of the next chapter…thanks again and hope to see you soon….

All the best

Paul  ;D


(http://i1315.photobucket.com/albums/t597/pjlucas1/photo1_zpsec213a81.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo1_zpsec213a81.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo2_zps692c9ccd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo2_zps692c9ccd.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo3_zps7fbabbef.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo3_zps7fbabbef.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: rudycob1 on July 13, 2014, 11:34:56 PM
All I can say is well done.
A fantastic job, a great build with plenty of detail and a superb looking car.
Now enjoy it.  :)
Title: Re: Paul's 4thirty Build Diary
Post by: NYAL F430 on July 14, 2014, 08:39:01 PM
Well done, enjoy the ride... ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on July 15, 2014, 10:07:30 AM
Not only a superb build but a bible for future builders.  Congrats for two bril jobs.
Title: Re: Paul's 4thirty Build Diary
Post by: beemaman on July 15, 2014, 09:32:23 PM
First class Paul a quality build you'd put a lot of top builders to shame.looking forward to seeing this great car :)
Title: Re: Paul's 4thirty Build Diary
Post by: ferrari feb 14 on July 18, 2014, 08:51:40 AM
Fantastic job Paul great to see it finished you should be proud  enjoy, hope to be at donnington so might see you there ,cheers jd (ferrari 360jd)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 25, 2014, 10:22:20 PM
Been a while but here are a couple more updates:

On the roof t-brackets, I riveted on the metal pieces to stop them coming out through the top of the rear deck. I basically put the t brackets in the right position for when the roof is on, and then when I lifted the rear deck I riveted the metal pieces accordingly so the brackets couldn’t possibly go any higher. That means when I raise the brackets again and I push them as far they can go I know that they are going to be in the correct position. 

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9012_zps4d4bb3b9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9012_zps4d4bb3b9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9029_zpscd6ed8fd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9029_zpscd6ed8fd.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9030_zps48216186.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9030_zps48216186.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9032_zpsedaa193d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9032_zpsedaa193d.jpg.html)


Also made some mirror backing plates. I nicked Beany’s idea of using a chopping board, cut to size (slightly smaller than the area), added some shallow holes in the back for the glue to bite one, covered in carbon fibre wrap, and then around the edge I stuck some d-rubber.  These aren’t perfect but they look better than the photos. The triangle part is a very awkward shape and would probably take an absolute life-time to shape-perfectly out of the chopping board. By using the d-rubber helps filled the awkward edges and also presses up against window to form sort of a seal.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9013_zpsce0c1aff.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9013_zpsce0c1aff.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9014_zps12436b66.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9014_zps12436b66.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9015_zpsdf9ab2e1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9015_zpsdf9ab2e1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9016_zpsc203b225.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9016_zpsc203b225.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9017_zpsf039e381.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9017_zpsf039e381.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9019_zps3618c5f5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9019_zps3618c5f5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9020_zpsdfb07f81.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9020_zpsdfb07f81.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9021_zps382864b1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9021_zps382864b1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9025_zps17d408be.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9025_zps17d408be.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9028_zps8a5e4edc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9028_zps8a5e4edc.jpg.html)


I also added safety strap to the other side as well on the rear deck. So now I’ve got 2:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9033_zpsb1e11651.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9033_zpsb1e11651.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9034_zps33ced206.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9034_zps33ced206.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 26, 2014, 09:38:47 AM
As you may remember, to help future builders, I was going to log how long my build took in hours. I haven't added the numbers on my updates for a while, but I still have been tracking it all. So now the car is done here are some stats:

The car was built in 466 hours over 15 months - April 2013 to July 2014

This is the equivalent of 58, full 8 hour days

Hours spent before painting: 310

Hours spent on dummy engine alone: 14

I have an excel spreadsheet that I kept during the build for logging my hours, plus each update had a brief description of what I did so it shows in what order I did things.

However - I can't seem to attach it. Tenpin could you maybe help me here?
Title: Re: Paul's 4thirty Build Diary
Post by: Lord Beany on July 26, 2014, 10:12:52 AM
Great work Paul,

I like the check strap idea. With the top down at 80mph (private road naturally) I do notice some movement in the pod area of the rear deck so i do wonder if I'm about to deploy the worlds biggest airbrake ay any moment. Might exchange this idea for my chopping board one if you don't mind, lol?

Fantastic build thread mate.

Beany ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on July 26, 2014, 02:36:26 PM
I think that is a fair trade matey.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 01, 2014, 10:55:32 PM
Time for some more pictures…… ;D

On my rear deck safety straps, when the roof was up, I wanted to see if they could be still attached to something. With the roof up the rear deck is more secure as it has the roof over it, but I discovered that the safety straps could be clipped to the hooks that the rear gloves boxes lock to! Result! Plus it doesn’t stop the gloves boxes closing properly and the way they lie, the straps also lie clear of the rear deck pods that are folded down underneath.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9035_zps38c2359f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9035_zps38c2359f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9036_zpsf29bdbda.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9036_zpsf29bdbda.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9037_zpsc3fc1cfa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9037_zpsc3fc1cfa.jpg.html)


Next…it seems the cat has moved into the garage…grrrrr

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9038_zps20054e64.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9038_zps20054e64.jpg.html)


Two weeks ago I was duty to take my nephew to his end of school prom. So this gave me the chance to clean the car for the first time. Also took my eldest daughter out for a spin.

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo1a_zpsabcebdb0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo1a_zpsabcebdb0.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo2a_zpsb95a8188.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo2a_zpsb95a8188.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo3a_zps33deeb9a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo3a_zps33deeb9a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo4a_zpsd6d93def.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo4a_zpsd6d93def.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo5a_zps099eed83.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo5a_zps099eed83.jpg.html)


Last Friday I threw caution into the wind and drove the car into central London to show all my work colleagues. It was the least I could do as they have been very interested in the project over the last 15 months.  The journey in was fine as I arrived at work at 630am, but the journey home was horrendous. Rush hour on a Friday, in central London, is a bit of nightmare. Took 45 mins before I could change into 3rd gear, and there were buses and bikes everywhere. I was a nervous wreck by the time I got home. The car? Never missed a beat and she took it all in her stride! The car spent the day safe in the work underground car park amongst some nice motors that included a GT40. Leaving the car park was a bit of an event as all my colleagues were positioned at the bar opposite the exit ramp to wave me off. I had never been so nervous on a hill start! LOL


(http://i1315.photobucket.com/albums/t597/pjlucas1/DSC_3722_zps5b11dd47.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/DSC_3722_zps5b11dd47.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo1_zps87395d38.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo1_zps87395d38.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/ad18bf60-1d0a-4a2d-a0fa-aa916bb94db3_zps04c41984.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/ad18bf60-1d0a-4a2d-a0fa-aa916bb94db3_zps04c41984.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo4_zps2a254d36.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo4_zps2a254d36.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo3_zps430e0382.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo3_zps430e0382.jpg.html)


Also heard today that the insurance has finally given me an agreed value on the car, so I can rest a little easy now.  ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Wizard on August 01, 2014, 11:52:40 PM
Paul, honestly your car looks absolutely amazing.  If it was me I wouldn't have changed to 3rd gear at all. I would have found every traffic jam just so I could drive slow in order to show the car off. Looks stunning
Title: Re: Paul's 4thirty Build Diary
Post by: Commando on August 02, 2014, 12:51:46 AM
Wow... Total head turner. Well done that man
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on August 02, 2014, 07:42:14 AM
What's the problem with the cat.  It makes your car another Furrari. :-)
Cats know quality when they see it.

M
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 02, 2014, 06:45:42 PM
***QUESTION GUYS****. Does anyone know whether it is possible to turn off the mr2 passenger air bag? And if so, how is it done? Cheers guys.
Paulie.
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on August 02, 2014, 08:42:50 PM
i will be disconnecting the power from mine and maybe even removing it.....
Title: Re: Paul's 4thirty Build Diary
Post by: ghall164 on August 03, 2014, 06:07:05 PM
 :o just seen the photos she's a beauty well done you must be so proud of all your hard work well worth the 15 month build fantastic job Paul  :D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 06, 2014, 10:38:24 PM
Whilst driving around recently, I noticed that there was an annoying squeaking sound every time I went over a rough bit of road.  I initially thought it was something on the dash board but I eventually traced it to the bonnet catch. Basically the metal loop in the bonnet was rubbing on the metal of the bonnet catch causing the squeak

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo3_zps52f448d5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo3_zps52f448d5.jpg.html)


To stop metal on metal I thought I’d cover the metal loop in amalgamation tape which is rubber and now there is no squeak.  Sorted! I guess over time the rubber tape will wear but it is a quick fix to replace it.

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo4a_zps97d007d2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo4a_zps97d007d2.jpg.html)


Also added some D rubber here so the bonnet doesn’t bang against the other part of the body work whilst closed

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo5_zps6d27be5d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo5_zps6d27be5d.jpg.html)


Bought a new number plate for the car to hide the age, so fitted this up at the weekend. R200 doesn’t mean anything really, well maybe Red and 200mph? But PJL is my initials. LOL

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo_zps10f39ea8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo_zps10f39ea8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo1_zps2d294ea9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo1_zps2d294ea9.jpg.html)

So at the weekend I took the car over to my Mum’s who hadn’t seen it in its finished state and took her for a spin. The drive over was great fun, plenty of head-turning and when I passed a real 360 on the road (red with beige seats) and he was waving and giving the thumbs up at me like mad. How I did chuckle  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/001_zpsa0050c06.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/001_zpsa0050c06.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/003_zps4105e9fb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/003_zps4105e9fb.jpg.html)

Mum:

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo2_zpsba0a070d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo2_zpsba0a070d.jpg.html)

And then last night I took the finished car back to Dad’s, the place where it was born, to show his neighbour Terry the welder, who if you may remember, did some welding on the doors for me a year ago.  Terry has a mini F40 kit car with a V8 in it build 30 years ago on a Triumph TR7. Painted of course in Rosso Corsa. He loved my car and couldn’t believe what it looked like. However he was very upset when I told him the brakes were fake, as he had thought these were real. This really did please me as he is a mechanic and has built numerous cars over the years!!!

(http://i1315.photobucket.com/albums/t597/pjlucas1/Ferrari006_zps388ee419.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/Ferrari006_zps388ee419.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/Ferrari005_zpscf459726.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/Ferrari005_zpscf459726.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/Ferrari008_zps1e929ad0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/Ferrari008_zps1e929ad0.jpg.html)


Car back at Dad’s

(http://i1315.photobucket.com/albums/t597/pjlucas1/Ferrari009_zps7a60d147.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/Ferrari009_zps7a60d147.jpg.html)


And finally a picture of the dream team!

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo2a_zps67608ea6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo2a_zps67608ea6.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Phils99 on August 07, 2014, 08:27:53 AM
great pics yet again mate, looking forward to seeing her for real at Donnington!
Title: Re: Paul's 4thirty Build Diary
Post by: MADMAN on August 07, 2014, 03:05:04 PM
First class build Paul n Dad, two very proud looking guys, well done.
See you at Donnnington
MADMAN 8)
Title: Re: Paul's 4thirty Build Diary
Post by: Monster on August 07, 2014, 05:55:53 PM
Paul
Really nice looking car, you are right to be proud of it.
Another red 430 for the DNA OC stand at Donnington.
See you there.
Mark
Title: Re: Paul's 4thirty Build Diary
Post by: Commando on August 07, 2014, 10:50:40 PM
Really great job, Looks stunning. Well done
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 10, 2014, 07:25:35 AM
Thanks for all the great comments Guys. Now we just need to pray there is no rain at Donnington!!!  :-\
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 10, 2014, 07:27:39 AM
Right, I've finally managed to upload the Excel spreadsheet, that I kept whilst doing the build where I logged all the hours and what was done at each stage of the build. Hope this helps someone.  ;D

It's attached below this text....
Title: Re: Paul's 4thirty Build Diary
Post by: Wizard on August 10, 2014, 08:13:51 AM
Wow. That is very detailed.

You clearly have to much spare time. Lol
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 10, 2014, 08:31:23 AM
Haha, the spreadhseet was compiled over 15 months. The problem I had was remembering to do it each time.. ::). I've certainly got more spare time now the car is done... ;D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 10, 2014, 08:42:46 AM
I thought I’d mention this in case others run into the same problem. I noticed that when my roof T-brackets were lowered down flush with the rear deck, once I had riveted on the piece of metal to stop the brackets coming out from the top, the brackets were catching on the inside body of the car and scratching it when the deck was closed.

This bit:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9062_zps4218763c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9062_zps4218763c.jpg.html)

…was rubbing here

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9063_zps0dfa1fbe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9063_zps0dfa1fbe.jpg.html)

Obviously this is ultimately due to how my rear deck frame was put on all that time ago. Anyway it wasn’t a big deal but I decided to drill out the rivets and place the metal piece on the other side. It now clears and I touched up the scratches.

 (http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9064_zpsb94e14a0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9064_zpsb94e14a0.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9065_zps444a9b62.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9065_zps444a9b62.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9066_zps9991b940.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9066_zps9991b940.jpg.html)


You may have noticed I haven’t got a thumbscrew here.. I dropped it and lost it, so now I use nuts instead and keep a spanner in the glove box.  Works fine and I can tighten it up more, thus make the roof T-brackets nice and tight.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9067_zpsd6a0ef3b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9067_zpsd6a0ef3b.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 10, 2014, 09:12:40 AM
Did some interior touches yesterday. Firstly I changed the heater dials. I didn’t like the standard white ones, so changed them to black ones. I bought these from a company called Metal Monkey. Great service from these guys. I ordered the dials Friday lunchtime and they arrived Saturday morning. Link below:

http://www.metal-monkey.co.uk/acatalog/copy_of_copy_of_MR2_MK3_Heater_Dials.html


Standard dials below, pull the knobs off and undo the screws arrowed. Then the whole surround comes away with a little tug. It has clips at each corner. Be careful of the wire connecting the digital clock

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9040_zpsaa5253a0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9040_zpsaa5253a0.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9041_zps0b1dcf25.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9041_zps0b1dcf25.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9042_zpsa90d0fac.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9042_zpsa90d0fac.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9043_zps7cf25373.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9043_zps7cf25373.jpg.html)


There are full instructions with the dials but this is what I did. You need to remove the metal rings around before you can change the dials. These metal rings are held on with plastic rivets. Turn the piece over and you’ll see them

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9044_zps00770b17.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9044_zps00770b17.jpg.html)


You just need to trim off these rivets with a knife and then the rings will come away

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9045_zpsd45b72a4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9045_zpsd45b72a4.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9046_zpsc35a3abe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9046_zpsc35a3abe.jpg.html)


All removed

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9048_zps7a379b3a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9048_zps7a379b3a.jpg.html)


The dials are just stuck on. I just eased them off by pushing from behind and they come away. The new ones are direct replacements. Just carefully stick them back on.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9049_zpsdf806a75.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9049_zpsdf806a75.jpg.html)


Add the rings back and then where the plastic rivets were on the reverse, just add a dab of superglue to keep them in place

(http://i1315.photobucket.com/albums/t597/pjlucas1/7_zpsef80d0da.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/7_zpsef80d0da.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9051_zps20cbadee.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9051_zps20cbadee.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9052_zps9f54126b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9052_zps9f54126b.jpg.html)


Almost forgot, also added some MADMAN knobs as a finishing touch  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo_zpsc7dbef6e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo_zpsc7dbef6e.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 10, 2014, 09:16:13 AM
I also got these rings to go around the speedo holes. I definitely recommend this cheap mod. It totally transforms the speedo surround

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9055_zps7f37a1e3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9055_zps7f37a1e3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9056_zps5ccbc955.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9056_zps5ccbc955.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9058_zps88ed379a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9058_zps88ed379a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9061_zps3cf23c5c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9061_zps3cf23c5c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/4_zpsb3b7c00f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/4_zpsb3b7c00f.jpg.html)


So here we go – both mods together. Very pleased with these little touches

(http://i1315.photobucket.com/albums/t597/pjlucas1/5_zps7ba8c8ce.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/5_zps7ba8c8ce.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo2_zps2f71eada.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo2_zps2f71eada.jpg.html)
Title: Re: Paul's 4thirty Build Diary
Post by: Wizard on August 10, 2014, 10:00:32 AM
Looks fantastic. Helps transform the car interior.

All you need now is one of Madmans H gates....
Title: Re: Paul's 4thirty Build Diary
Post by: Darren on August 10, 2014, 10:39:54 AM
Very nice job, it seems even with all the new stuff DNA come out with, the 430 is still a favourite. I like all their models, but think the overall package of the kit and it's final look still takes some beating.
Well done.
D
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on August 10, 2014, 11:06:58 AM
Paul.
I visited this lady when I was trying to transform the instruments for the new Furrari.  Nice work but she couldn't help me due to the 3D shape of SL dials.  Nobody else could either.
Title: Re: Paul's 4thirty Build Diary
Post by: Darren on August 10, 2014, 11:58:36 AM
I've posted about this artist before, he's going to design my dials
http://www.reapautomotivedesign.com/
If you really want to change the dial backs of the Merc, he may be able to help, Lockwood go to him for 'special projects' Please bear in mind he's not cheap. Each design is a hand drawn silk screen, initial cost is high but copies of that design are cheap.
D
Title: Re: Paul's 4thirty Build Diary
Post by: Furrari on August 10, 2014, 12:51:05 PM
Dangerous.  I did speak to these people.  They gave me a starting price of £800 +, so I gave it a miss.

If you look on my build thread you see I have just put a couple of decals on, cost me £1. And is still bespoke.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 10, 2014, 06:53:31 PM
***AWESOME***

Just found out some good news. As we all know, one of the things that is a shame is the tax disc on our cars says Toyota (or Ford, Mercedes etc..). When people look around my car, a lot of them do spot the word Toyota on the disc. 

30 minutes ago I started the process of getting my car's name changed with the DVLA. I managed to find the relevant details on the net and sent them off an email. Once done I got the usual automated email from them.

At the bottom of the email was this!

https://www.gov.uk/government/news/vehicle-tax-changes

Hooray! From the 1st October 2014 we wont need to put a tax disc on our cars. So therefore there is one less place the word Toyota (Ford/Mercedes) appears. So now I wont bother with the vehicle name change. I don't care what is says on some computer system as long as on the car it doesn't say Toyota
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 15, 2014, 07:22:23 PM
***Help please Guys***

I've noticed that when I turn my steering wheel left or right from straight whilst driving along there is a small knocking sound that seems to be coming from the steering column. It doesn't seem to be coming from inside the car, it seems further down under the bonnet, near the rack. It only knocks on the first revolution from straight and occurs when turning left and right. The car is having an oil change on monday and i will get the garage to look at it. But any idea/help as to what it is would be much appreciated. Does it sound dangerous? I drove the car approx. 30 miles today and it was fine apart from this annoying knocking noise. Would low power steering fluid level be the cause? Thanks in advance as always...

Paulie
Title: Re: Paul's 4thirty Build Diary
Post by: Darren on August 16, 2014, 09:56:58 AM
The toyota steering racks are quite reliable, I'd check track rod ends, ball joints the Mcphearson strut bearing, plus all your nuts and bolts, shouldn't take too long.
D
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 17, 2014, 09:07:38 PM
Thanks Darren. Taking it in tomorrow morning so will let you know how it goes.
Title: Re: Paul's 4thirty Build Diary
Post by: Paul79 on August 18, 2014, 11:59:10 AM
Doctor Dangerrous's diagnosis was correct. It was a loose track rod end. All sorted now
Title: Re: Paul's 4thirty Build Diary
Post by: Wizard on August 18, 2014, 12:24:27 PM
Fantastic.

No excuses now, put the top down and go driving
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 21, 2014, 10:24:24 PM
***WHAT HAVE I DONE???***

Just paid a deposit for a V6.  ;)
Title: Re: Paul's 4thirty Build
Post by: Wizard on August 22, 2014, 05:23:04 AM
Fantastic. Your car just gets better and better.....!
Title: Re: Paul's 4thirty Build
Post by: Phils99 on August 22, 2014, 08:37:27 AM
OMG!!! well done mate!!
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on August 22, 2014, 03:39:56 PM
You will not regret it mate.
Took mine out for a spin yesterday and its an instant grin machine.
We will have a V6 members area soon at this rate :-)
Title: Re: Paul's 4thirty Build
Post by: beemaman on August 22, 2014, 05:10:27 PM
well done paul you will have the awesome combination then just like beany and rudy plus the other v6 converts :)

becoming a familiar thing now you posh (cant say the other word) lol :)
Title: Re: Paul's 4thirty Build
Post by: ghall164 on August 22, 2014, 05:25:05 PM
 :) nice one Paul looks and performance what more could you want  ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 14, 2014, 07:49:02 AM
Been doing a few little jobs on the car to try and get rid of the various rattles that crop up. These sort of things you only start to notice once you use the car for a bit.

I’ve lined the inside of the glove box with felt.

(http://i1315.photobucket.com/albums/t597/pjlucas1/1_zps48cdcb16.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/1_zps48cdcb16.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/2_zps2f61f4b4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/2_zps2f61f4b4.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/3_zps7820770a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/3_zps7820770a.jpg.html)


I undid these bolts are the side of the dash, made the hole slightly bigger and pushed the whole dashboard forward. This is a tip I found on the MR2ROC. This helps stops rattles on the top of the dashboard:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9081_zpse49c63d4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9081_zpse49c63d4.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9083_zps0fcd8efb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9083_zps0fcd8efb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9085_zps0c575e33.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9085_zps0c575e33.jpg.html)


Added foam tape to various places, fuse box cover and inside the bottom of the a-trim pillars

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9089_zpsfd2192d0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9089_zpsfd2192d0.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9074_zpsb8683132.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9074_zpsb8683132.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9075_zps5cc50a80.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9075_zps5cc50a80.jpg.html)


Another tip from the MR2ROC was to add sponge behind the speedo to stop this black plastic tube that supplies the heater vents with air banging the dash from underneath

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9077_zpsdb615edb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9077_zpsdb615edb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9078_zps66b687fb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9078_zps66b687fb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9079_zpsc65d5060.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9079_zpsc65d5060.jpg.html)


D-rubber added on the rear storage boxes lids:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9071_zps2e316f6a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9071_zps2e316f6a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9073_zpsd9f4a3f4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9073_zpsd9f4a3f4.jpg.html)


Added foam tape to rear deck catches. Stops the sound of metal-on-metal squeaks

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9072_zps0529d771.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9072_zps0529d771.jpg.html)


Added various bits of rubber trim/foam tape around the steering wheel area:

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo1_zpsd07b04c9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo1_zpsd07b04c9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo2_zpscbfbbc6d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo2_zpscbfbbc6d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo3_zps3170dbc9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo3_zps3170dbc9.jpg.html)


Also on the speedo cover

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9091_zpsb6439d48.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9091_zpsb6439d48.jpg.html)


Finally, I added a mirror for my better half on the passenger sun-visor

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9080_zps37d7d192.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9080_zps37d7d192.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9086_zpsad027a36.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9086_zpsad027a36.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Wizard on September 14, 2014, 08:51:40 AM
Paul, as always your attention to detail is fantastic. Again you have applied simple/effective and cheap solutions for the problem. Excellent
Title: Re: Paul's 4thirty Build
Post by: seriph on September 14, 2014, 10:03:33 AM
This is more than the big "F" do mate!  -  their chariots rattle n hum all the time when driving!

:)

Title: Re: Paul's 4thirty Build
Post by: Furrari on September 14, 2014, 10:20:23 AM
I had lots of squeaks on the boot and bonnet with the panels moving on the rubber stops due to the poor roads around here.  A bit of white, electrical or brake, non creep grease on the stops cured this.  As it's a clean grease you could also put a trace of it around the door and roof seals.

Forgot to say that a trace of white grease or Vaseline on the door seals also stops them sticking in freezing weather.
Title: Re: Paul's 4thirty Build
Post by: Phils99 on September 14, 2014, 10:30:23 AM
Excellent sound proofing "how to" mate....another guide I will be following when I do mine!
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 14, 2014, 12:00:11 PM
cheers Guys - it is still much a work in progress, but any other tips I find, I'll put on here for all to see.

Forget - here are a couple more pictures from Donnington.  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9099_zpsff2d24a9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9099_zpsff2d24a9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_9101_zps7d65acaa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_9101_zps7d65acaa.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: ghall164 on September 14, 2014, 11:55:08 PM
 ;) great pictures Paul
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 05, 2014, 08:01:01 AM
Morning everyone! It’s been a while so I thought I’d update you on some of the little jobs I’ve been up to.

I decided to paint the inside of the rear deck satin black. This is definitely a job to do before you bond the rear deck on but never mind. But it looks 100x better all being nice and black under there as opposed to the light grey of the fibre glass – a lot more factory looking.


Before – I also tidied up some of the wayward bonding agent

(http://i1315.photobucket.com/albums/t597/pjlucas1/8_zpsa4608857.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/8_zpsa4608857.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/9_zps7f6da0f3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/9_zps7f6da0f3.jpg.html)


Afterwards

(http://i1315.photobucket.com/albums/t597/pjlucas1/5_zpsba83cfd0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/5_zpsba83cfd0.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/11_zps8777e2ba.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/11_zps8777e2ba.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/12_zps1eb6ea5d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/12_zps1eb6ea5d.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 05, 2014, 08:47:14 AM
Rear Deck Safety Strap 2.0

Some of you may remember the rear deck safety strap I devised a while back, using eye bolts, clips and heavy duty bicycle chains? (You can see the chains hanging down in the previous pictures). Well, whilst they do the job (sort of) I wanted to see if there was a better way.

I leveraged off an idea that Andy who has V8 KLR had used. The problems with the bicycle chains are:

a) When the rear deck is up they hang down and look a bit unsightly
b) They are heavy
c) They wouldn’t actually stop the rear decking from coming open to start with, they just stop it opening fully should the worst happen.

What would be better is a solution that is designed to pull the deck shut tight all the time.  Like Andy had done I wanted to utilise the rear window strap method and have everything done inside the rear glove boxes. I looked at the slot in the roll bar metal bracket where the window straps pass through and these are big enough to take another strap. Likewise the slots in the roll bar cover are big enough to also take another strap. So the plan was to have another set of ratchet straps inside the glove boxes to tighten off the rear deck just like I have done with the rear window.

With this decided I then turned my attention to where I would attach these straps to on the rear deck frame. The problem with the 430 rear deck frame there is nothing for anything to clip on to it. Unlike the 360 one there is no lip.  So I had the idea of buying a cleat hook and then riveting it to the frame in the right position

(http://i1315.photobucket.com/albums/t597/pjlucas1/16_zps0d6c25df.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/16_zps0d6c25df.jpg.html)


This is only possible if you have a gap between your rear frame and rear deck like I seem to have on mine. See arrow below.  Then there is room for the other side of the rivet to go. If it was flush then this wouldn’t be possible.  

(http://i1315.photobucket.com/albums/t597/pjlucas1/43_zpse1f560c0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/43_zpse1f560c0.jpg.html)


I bought some new luggage ratchet straps off eBay and at one end made a loop and riveted firmly in place.

(http://i1315.photobucket.com/albums/t597/pjlucas1/13_zps4e67d308.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/13_zps4e67d308.jpg.html)

The other end of the strap I cut off and bolted to the bolt in the rear storage bins just like I had done for my rear window straps

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo_zps54fd4dd7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo_zps54fd4dd7.jpg.html)


I threaded the straps through the metal slot in the roll bar bracket and down into the storage bin through the slot in the roll bar cover and then attached to the other ratchet-strap end

(http://i1315.photobucket.com/albums/t597/pjlucas1/44_zps525b7891.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/44_zps525b7891.jpg.html)


So now when closing the rear deck, close it enough so you can hook the loop end onto the cleat hook, close the rear deck and then tighten off inside the storage bin.

(http://i1315.photobucket.com/albums/t597/pjlucas1/45_zps62ea73ab.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/45_zps62ea73ab.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/46_zps4458d469.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/46_zps4458d469.jpg.html)


To open the rear deck, you loosen the straps a certain amount, pull the deck open unloop the straps and open the deck fully.

I still need to do the other side, but you get the idea.  ;D
Title: Re: Paul's 4thirty Build
Post by: ferrari feb 14 on October 05, 2014, 09:14:36 AM
Great work as always Paul ,jd
Title: Re: Paul's 4thirty Build
Post by: ghall164 on October 05, 2014, 09:07:32 PM
 :) very well executed Paul
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 06, 2014, 09:51:04 PM
I shot this video of the safety strap set up for someone, so thought I'd share with all:

https://www.youtube.com/watch?v=VjJS_ArRMeU&list=UUhEAgdqSrdd8pBVdFi7pU6Q

Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 10, 2014, 12:23:42 PM
Quick V6 update. A donor RX300 VVTI engine has been sourced by Woodsport and it is sitting in their workshop. It will be stripped, painted and rebuilt by end of November hopefully.  ;D
Title: Re: Paul's 4thirty Build
Post by: Wizard on October 10, 2014, 12:34:58 PM
Fantastic. Any idea when your car will be going in to Woodsport is it likely to be late this year or early next?
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on October 10, 2014, 04:24:02 PM
Well done mate. It will be transformed.  :D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 11, 2014, 08:46:07 AM
Fantastic. Any idea when your car will be going in to Woodsport is it likely to be late this year or early next?

Early next year at the moment, but maybe it can be brought forward. Will have to check with Paul.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 11, 2014, 08:51:50 AM
Over the past few weeks I have been busy on another project – redoing my scuttle cover.

There are a number of reasons for this
1)   The side parts that need to be extended where scuffed when fitted originally and the filler had cracked
2)   The centre part has no grill, just a hole where it was cut back to clear the bonnet
3)   I didn’t really like the wipers I had, they are not like the real car and as the washer jets were on the wipers themselves and I had the pipes showing which I also thought less factory looking
4)   I wanted to have washer jets on the scuttle instead of the wipers

The grill is a very awkward shape, so the best idea is to use one from another scuttle cover if you can. I originally planned to redo the whole cover again from scratch so I bought another 2nd hand scuttle cover off eBay for around £25. However I soon realised it was probably less work to use the grill from the new cover on the old one and repair everything.

So here goes…..

These are the wipers I did have.  The jets are actually on the blade.  They don’t look great tbh. I really don't like the single blade type look.

(http://i1315.photobucket.com/albums/t597/pjlucas1/17_zps240f0b73.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/17_zps240f0b73.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/18_zpsb346b468.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/18_zpsb346b468.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/19_zps8b780838.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/19_zps8b780838.jpg.html)


Here is my original cover with the big gaping hole in the front. If I had known when I was trimming it back I would have kept the grill intact, but hey-ho.

(http://i1315.photobucket.com/albums/t597/pjlucas1/15_zps4f5d3edc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/15_zps4f5d3edc.jpg.html)


Here is the new scuttle cover, marked and ready to cut the grill out. At this point I was still going to rebuild it all from scratch, hence the cardboard templates trying to get the curve right

(http://i1315.photobucket.com/albums/t597/pjlucas1/1_zpsa31f2ffe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/1_zpsa31f2ffe.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/4_zpsd00c0e30.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/4_zpsd00c0e30.jpg.html)


I removed my original cover and started to repair the side extended bits. I thought about other ways to extend these bits down inside the wings, but in the end I liked the way I had done it originally – it just needed to look better. One of the problems I found is originally there was much more of a step at the circle below. I.e. the main part of the curved bit was a lot higher and was catching on the underside of the wing edge. As fitting the cover is a bit awkward, if it is tight there, it is going to get scratched and damaged again, so I flattened this step down a lot so it would clear the underside of the wing when fitting back. I also ground back a lot of the original filler and redid in flexible filler.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20_zps1e886388.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20_zps1e886388.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/22_zps81b4c439.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/22_zps81b4c439.jpg.html)

Here you can see I bonded in the new grill into the old cover. There are ribbed pieces of plastic on the inside of the hole then you need to trim off with a knife so the new grill can sit snug inside the hole. I bonded in with stika-flex.

(http://i1315.photobucket.com/albums/t597/pjlucas1/21_zps4f762c95.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/21_zps4f762c95.jpg.html)


Next I drilled holes for the washer jets. These are just secured with washers and nuts underneath. This is the best place for them as they are centre of windscreen and the grill area below gives room for the pipes to sit.

(http://i1315.photobucket.com/albums/t597/pjlucas1/23_zpsea4e40d3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/23_zpsea4e40d3.jpg.html)

Here are the jets from the top (arrows). The circle shows the how the second grill part is the same as the original part, just pushed further back inside. Not sure if that makes sense the picture should explain what I mean.

(http://i1315.photobucket.com/albums/t597/pjlucas1/24_zps8a8c03f4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/24_zps8a8c03f4.jpg.html)

The grill closer up

(http://i1315.photobucket.com/albums/t597/pjlucas1/25_zps44a79ca2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/25_zps44a79ca2.jpg.html)

To be continued later….
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 11, 2014, 06:51:58 PM
So next up I tried fitting back the cover and connecting up the washer jets. I rearranged the tubes so that only one came through the hole I had in the scuttle and then connected the T piece and connected 2 tubes off it to connect to the jets.

(http://i1315.photobucket.com/albums/t597/pjlucas1/36_zps26b2274b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/36_zps26b2274b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/37_zps2e6e0476.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/37_zps2e6e0476.jpg.html)


Connected the jets up

(http://i1315.photobucket.com/albums/t597/pjlucas1/38_zpsbd3f3e7a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/38_zpsbd3f3e7a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/40_zps6dc6c667.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/40_zps6dc6c667.jpg.html)


And then I fitted the cover back in place

(http://i1315.photobucket.com/albums/t597/pjlucas1/26_zpsd7823fef.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/26_zpsd7823fef.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/27_zps8cc9a0ce.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/27_zps8cc9a0ce.jpg.html)


I recommend cutting away this lower part of the cover so it is easier to fit back over the bolt that the driver’s wiper connects to. Otherwise if you leave it as a complete circle hole you’ll have to do more movement to get it over the bolt that sticks out. The more movement you have to do the bugger risk there is of scratching the edge bits. I planned to paint the scuttle beneath it black including the bolts so it doesn’t show through.

(http://i1315.photobucket.com/albums/t597/pjlucas1/28_zps8e495754.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/28_zps8e495754.jpg.html)


Here are the edge bits I was talking about. I have lowered the profile so it now fits under the lip of the wing where my finger is.

(http://i1315.photobucket.com/albums/t597/pjlucas1/29_zps64323bad.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/29_zps64323bad.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/30_zps1ac61c4f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/30_zps1ac61c4f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/31_zpsbdd7d4e2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/31_zpsbdd7d4e2.jpg.html)


Then I closed the bonnet to see how things lay – I was very pleased, especially with the grill in the middle

(http://i1315.photobucket.com/albums/t597/pjlucas1/33_zpsa7864ed3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/33_zpsa7864ed3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/34_zpsa1e07206.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/34_zpsa1e07206.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/35_zps3116e5d0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/35_zps3116e5d0.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 11, 2014, 07:12:12 PM
Video of the washer jets working

https://www.youtube.com/watch?v=e0BtEi0fojo&list=UUhEAgdqSrdd8pBVdFi7pU6Q

Title: Re: Paul's 4thirty Build
Post by: Phils99 on October 11, 2014, 07:20:50 PM
Great job mate, you got me rethinking my washer jets now......

When you cut out the middle grill from the "new" scuttle, as you laid it on top of the plastic on your original grill, isnt it higher up at the edge nearest the windscreen? have you added a rubber edging strip round it?
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 11, 2014, 07:25:37 PM
i know what you mean Phil. I have literally put another whole scuttle grill inside the another and sunk it in further back. So in theory the top part of the scuttle where the grill is, is higher than it would have been on an MR2. I did put a rubber u-channel along the edge just to make it neater. what this space...just about to update again.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 11, 2014, 07:29:11 PM

So next was to paint the cover and also scuttle underneath in satin black. I focused particularly on this area as this would show through under the cover.

(http://i1315.photobucket.com/albums/t597/pjlucas1/42_zps6dce9618.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/42_zps6dce9618.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/41_zps57fc7b3d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/41_zps57fc7b3d.jpg.html)


All painted up

(http://i1315.photobucket.com/albums/t597/pjlucas1/55_zpsb03800b2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/55_zpsb03800b2.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/56_zps4dbda84d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/56_zps4dbda84d.jpg.html)


Painting the cover: once primed I used textured bumper paint. This stuff is fantastic.  The edge bits where I filled down, I just couldn’t get perfectly flat. Normal paint shows up everything but this stuff hides all that and actually makes it all look like textured plastic again even though there is filler in there. I thoroughly recommend it.  Here is what I bought on eBay

http://www.ebay.co.uk/itm/360399194758?_trksid=p2060778.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT


Primed

(http://i1315.photobucket.com/albums/t597/pjlucas1/48_zpsb1c85a3a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/48_zpsb1c85a3a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/49_zpsebd1afc4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/49_zpsebd1afc4.jpg.html)


Painted

Here you can see where i have really taken away that step part that would catch on the underside of the wing


(http://i1315.photobucket.com/albums/t597/pjlucas1/51_zps3cbcad51.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/51_zps3cbcad51.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/52_zps29066ba6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/52_zps29066ba6.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/54_zps0db60265.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/54_zps0db60265.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 11, 2014, 08:23:02 PM
So then it was time to fit it back for good. I masked up the edge bits just in case.

(http://i1315.photobucket.com/albums/t597/pjlucas1/53_zps48445aac.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/53_zps48445aac.jpg.html)


I connected the jets up and the carefully manoeuvred back into place.

(http://i1315.photobucket.com/albums/t597/pjlucas1/57_zps09435b73.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/57_zps09435b73.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/58_zps59c8c386.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/58_zps59c8c386.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/59_zps63877016.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/59_zps63877016.jpg.html)


Added back the wiper arms and then put back on some normal wiper blades

(http://i1315.photobucket.com/albums/t597/pjlucas1/63_zps2bd11752.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/63_zps2bd11752.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/64_zpsa770c0df.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/64_zpsa770c0df.jpg.html)


And we are all done  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/65_zps438d8d82.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/65_zps438d8d82.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/66_zpsda4e4505.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/66_zpsda4e4505.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/67_zps02daffdc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/67_zps02daffdc.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Lee22 on October 11, 2014, 08:42:55 PM
As always, super detailed Paul.

Looks fantastic mate.
Some hard work done, and its paid off.....
Lee
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 11, 2014, 09:51:36 PM
I'm going update CRAAAAAZY today!!!!  ;D

Today I also finished off my rear deck safety straps. No more bike chains! Now the car has it's own set of red braces...  8)

Added the other cleat hook. Again I stress this is only possible if you have a gap between the fibreglass deck and the metal frame. Re did the other one with fatter shorter rivets. Now they are solid.

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo1_zps4574efa4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo1_zps4574efa4.jpg.html)


Then I just simply connected the straps up

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo3_zps299624c0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo3_zps299624c0.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo2_zpsbd58146c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo2_zpsbd58146c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo5_zps62023e47.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo5_zps62023e47.jpg.html)


Fully closed and tied off

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo4_zpscdad243b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo4_zpscdad243b.jpg.html)


These can also be used when the roof is up as well as there are 2 separate sets of rachets so both deck and rear window can be secured at the same time
Title: Re: Paul's 4thirty Build
Post by: beemaman on October 11, 2014, 10:02:10 PM
Great work Paul this is what it's all about buddy detail and commitment to details.

 it takes a different kind of person to produce a quality and detailed build.

Well done buddy much respect :)

A jobs ready at mine anytime..
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 11, 2014, 10:53:57 PM
What is so good about this photo?  ;D
Title: Re: Paul's 4thirty Build
Post by: Wizard on October 11, 2014, 11:23:41 PM
Paul,

The attention to detail is very impressive.  The mods look fantastic.  But I think you have taking this car modification thing way to far.  And by this I mean "you have a child booster seat in your trunk". Please don't tell me you have come up with a way to make this a 3 seater Ferrari????

On a serious note, the quality of your work throughout this build have been excellent.  I have read through your build thread many times and still learn new things every time I read it.  Top job as always.

Title: Re: Paul's 4thirty Build
Post by: V8 KLR on October 12, 2014, 01:41:25 PM
Look good mate,  :D I am going to start looking at my idea of the air vents soon..... ::)
Title: Re: Paul's 4thirty Build
Post by: Furrari on October 12, 2014, 03:10:09 PM
Paul.
I think this a bit like an ship in a bottle.  How do you
A) get the car in the garage
B) get yourself out of the car.
Mick
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 12, 2014, 06:40:38 PM
The answer to the photo riddle was...........NO TAX DISC........  now we are in October the law has changed and you no longer need to display it.  So no more Toyota written on the disc giving the game away.
Title: Re: Paul's 4thirty Build
Post by: Lee22 on October 12, 2014, 07:32:40 PM
Oh yes..
I didn't notice Paul........ ;D

I'll be taking mine out the second I go and see my car...!
It was the only give away..

I was never a fan of tax discs anyway
Lee
Title: Re: Paul's 4thirty Build
Post by: MADMAN on October 12, 2014, 09:33:49 PM
I never had one in mine, I used a beer bottle label  ;) ;)
MADMAN 8)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 13, 2014, 10:52:10 PM
Oh yes..
I didn't notice Paul........ ;D

I'll be taking mine out the second I go and see my car...!
It was the only give away..

I was never a fan of tax discs anyway
Lee

Haha. Lee. I only just realised that was you. You've changed your username!
Title: Re: Paul's 4thirty Build
Post by: Lee22 on October 14, 2014, 10:15:46 AM
Not sure if it was related Paul, but I started to get a lot of SPAM email.
Because my username is part of my email address, it makes me wonder if it hit from here, so I've changed my username  ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 18, 2014, 11:59:21 PM
Starter Button Wiring + Manettino Switch

Hi Guys.  I’ve been busy today sorting out my starter button and doing the wiring for it all.  The reason why is this: I never planned to wire the button up as I wasn’t that bothered about it to be honest. But I have now decided to change the air bag cover to black and also do the Manettino switch like Phil, so as my steering wheel was in pieces I thought it would make sense to have a go.  ;D

I’ve been chatting with Phil about it all and he told me it was very straight forward. There are instructions in the owners section from Beany which are great and are easy to follow. However we have a slight variation here as both Phil and I want to have the LED’s on the Manettino switch light up as well. You could wire them to the horn wire, but this is live all the time. You don’t really want that. What would be ideal is to have a 12V power than only comes on with the ignition to power the LED’s. Well as luck would have it, one of the MR2 air bag wires is exactly that!

I haven’t bothered to take photos of all of this – I went one better and shot a video of it.  I’ve been chatting with Phil about this and he created this great diagram showing exactly how it is all wired up. I have modified it slightly and here it is. If you want to wire up the starter button, I recommend looking in the owners section and reading Beany’s thread, and then reading this and watching the video. This should make things crystal clear. However (just putting a bit of a disclaimer here – just in case  :-\) if you are in any way not 100% confident you can do this, don’t and get an auto technician in to do it for you – I just don’t want to be accountable for anything that goes wrong!  ) . But put it this way -  If you can build one of these cars and get all the lights wired up etc.. then you can do this…  ;D

Here is the wiring diagram

(http://i1315.photobucket.com/albums/t597/pjlucas1/StarterWiringDiagram_zpse7395640.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/StarterWiringDiagram_zpse7395640.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 19, 2014, 12:07:03 AM
OK - so here is part 1. Apologies if I pronounce 'Manettino' wrong. I'm from Essex remember!!! LOL  ;D

https://www.youtube.com/watch?v=f_bFaq8sc90&list=UUhEAgdqSrdd8pBVdFi7pU6Q
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 19, 2014, 12:16:37 AM
and here is part 2. Night everyone. Enjoy!  ;D

https://www.youtube.com/watch?v=jOO_wnA8LFU&feature=youtu.be
Title: Re: Paul's 4thirty Build
Post by: Wizard on October 19, 2014, 10:04:44 AM
Paul/Phil.

Excellent work as always. I hope you know that from now on all your updates "must" be via YouTube. I know we all love photos, but you have raised the bar now. We all need videos from now on as they are simply fantastic.
Title: Re: Paul's 4thirty Build
Post by: Phils99 on October 19, 2014, 08:24:41 PM
Brilliant! Glad it all worked.....just need to get my car back and I can do mine!!
Title: Re: Paul's 4thirty Build
Post by: Lee22 on October 19, 2014, 10:01:01 PM
I just need to get mine back too and I can have a look at this mod as well.....

Oh yes, and try and understand how it works :-[. Electronics and me, are not the best of friends... But I have a good mate that laughs at this sort of thing..... (luckily)

Lee
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 23, 2014, 09:43:40 PM
So a couple of weeks ago I managed to buy a second hand one of these from eBay, and this Tuesday it finally arrived!

(http://i1315.photobucket.com/albums/t597/pjlucas1/1_zps3842910e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/1_zps3842910e.jpg.html)

So the first thing to do is rip it apart! LOL. However as I was doing this I made an unfortunate discovery. The Manettino switch (which was the main reason for the purchase) in this wheel had no LED’s! Boo. So the wiring I had done previously was now not needed. Never mind. I’m sure it will help someone in the future.

Basically there are 2 gaming wheels available. The 430 one and the 458 one. The 458 one is generally a cheaper one as it doesn’t have as many features as the 430 one. I think the 430 one has feedback rumble as well as a working Manettino switch. The 458 switch doesn’t turn all the way around. It is mounted on a spindle that is spring-loaded and you can turn it clockwise/anti-clockwise 1 notch and then it return to the middle setting. Having spent the money on this I wasn’t going to spend more money trying to buy a 430 one. Plus I think they are going up in price at the moment as a driving new game has just been released that would use it (accordingly to a work colleague who is a mad gamer!).

The 430 and 458 Manettino switches are also different. The 430 one the settings are grouped much closer together along the curve whereas the 458 one they are spread out more. I preferred the 458 look anyway. Just as well really as I’m stuck with it! Haha.

Anyway, taking it apart is pretty simple, just undo screws that hold the wheel to the base and then cut the inside wire and the wheel will come away, and then undo all the screws around the wheel edge and it will eventually come all apart.

(http://i1315.photobucket.com/albums/t597/pjlucas1/2_zps8f19c8bf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/2_zps8f19c8bf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/3_zps1a4378da.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/3_zps1a4378da.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/4_zps58ae57cb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/4_zps58ae57cb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/5_zps871e0cf1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/5_zps871e0cf1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/6_zps4106abed.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/6_zps4106abed.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/7_zps9404b2f4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/7_zps9404b2f4.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 23, 2014, 09:54:24 PM
Here is the DNA sticker versus the Xbox Manettino switch. The gaming wheel is only 70% the size of a real steering wheel, so everything is slightly smaller, including the switch. This is good, because the curve of the sticker is slightly too big and goes under the air bag cover

(http://i1315.photobucket.com/albums/t597/pjlucas1/4a_zpsa610e142.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/4a_zpsa610e142.jpg.html)

Once dismantled, I cut off the whole switch form the gaming wheel. The red knob just pulls off carefully and then the circuit board unscrews/comes away

(http://i1315.photobucket.com/albums/t597/pjlucas1/8_zps1f8b5594.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/8_zps1f8b5594.jpg.html)

Then I carefully removed the sticker from the plastic. BE REALLY CAREFUL HERE. Use a razor blade/sharp knife to gradually prise the sticker off and also do it slowly other you’ll scratch the colour from the sticker underneath and it will be ruined.

Here is the new one on top of the old showing just how much smaller it is.

(http://i1315.photobucket.com/albums/t597/pjlucas1/4b_zps815a975c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/4b_zps815a975c.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 23, 2014, 10:00:25 PM
So next was to size up the spindle holder so it would fit under the silver face plate. Like Phil,  I trimmed away loads of the black plastic. You really don’t need to leave too much, just enough to bond to the underside of the plate. The important bits are leaving the 2 spindle mounting points in place which the spindle/circuit board mounts to

(http://i1315.photobucket.com/albums/t597/pjlucas1/9_zps57c1eed8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/9_zps57c1eed8.jpg.html)

At first you’ll have 3 points but you need to get rid of one – see arrow

(http://i1315.photobucket.com/albums/t597/pjlucas1/10_zps3f17a152.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/10_zps3f17a152.jpg.html)

If you left it, it would get I the way of mounting the silver face pate back on the wheel

I tested the position of it by just taping it to the underside of the face plate

(http://i1315.photobucket.com/albums/t597/pjlucas1/11_zps5284780b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/11_zps5284780b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/12_zps4c91e741.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/12_zps4c91e741.jpg.html)

You want to ensure it is a far distance from the edge of the face plate, otherwise it will stop the plate fitting back snugly over the steering wheel cowling. You can see in the last picture all that is really left is a little 2-legged table.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 23, 2014, 10:05:25 PM
Then I cut out the spindle and circuit board. Again go as small as you can whilst still maintain the mounting holes

(http://i1315.photobucket.com/albums/t597/pjlucas1/13_zpscfe2d4c8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/13_zpscfe2d4c8.jpg.html)

Attached to the holder

(http://i1315.photobucket.com/albums/t597/pjlucas1/14_zps02b21fdc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/14_zps02b21fdc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/15_zpscea0b16c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/15_zpscea0b16c.jpg.html)

Try it for size first but you’ll definitely have to reduce the length of the legs to allow for the spindle to poke through the face plate enough to mount the red knob

(http://i1315.photobucket.com/albums/t597/pjlucas1/16_zps99339a9b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/16_zps99339a9b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/17_zpsd688b373.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/17_zpsd688b373.jpg.html)

As for the face plate hole, make it slightly bigger than the hole in the sticker so you have wiggle room to adjust. If you make it small than the sticker hole you’ll see face plate through it and your margin for error on mounting it finally is very small

(http://i1315.photobucket.com/albums/t597/pjlucas1/18_zps4e04549e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/18_zps4e04549e.jpg.html)

Put the sticker in place for the actually bonding so when you do it, you can put the red knob on and adjust it all nicely before the bond dries

(http://i1315.photobucket.com/albums/t597/pjlucas1/19_zps1dd3ed49.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/19_zps1dd3ed49.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20_zps35312f1a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20_zps35312f1a.jpg.html)

Done

(http://i1315.photobucket.com/albums/t597/pjlucas1/21_zpse6457fb3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/21_zpse6457fb3.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 23, 2014, 10:08:59 PM
Then I bonded in the starter button again

(http://i1315.photobucket.com/albums/t597/pjlucas1/23_zps67ce2a59.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/23_zps67ce2a59.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/24_zps9ad23ab8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/24_zps9ad23ab8.jpg.html)

While that was drying Dad sent a picture of the newly covered airbag cover in BLACK.

(http://i1315.photobucket.com/albums/t597/pjlucas1/22_zps75c3052c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/22_zps75c3052c.jpg.html)


Then it was just a case of trying it out for size! I’m really pleased with it. Looks much more factory

(http://i1315.photobucket.com/albums/t597/pjlucas1/28_zpsa00daa95.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/28_zpsa00daa95.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/25_zps81cf4d1d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/25_zps81cf4d1d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/26_zps875d6635.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/26_zps875d6635.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/27_zpsccb8179b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/27_zpsccb8179b.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 23, 2014, 10:10:53 PM
Just to compare. Old vs New   ;D

Title: Re: Paul's 4thirty Build
Post by: Wizard on October 23, 2014, 10:38:33 PM
Paul, excellent write up as always. It's worth keepin an eye on Ebay to see if a 430 comes up cheap as you have already put all the hard effort into the wiring etc
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 23, 2014, 10:41:50 PM
Cheers Ranj. You can buy me one for Christmas.  ;D
Title: Re: Paul's 4thirty Build
Post by: Lee22 on October 23, 2014, 10:54:27 PM
Now then Mr Wizard,

Let's not start bidding each other up on eBay..! ;D

I have my eye on 2 currently..! So hands off.. Lol
Title: Re: Paul's 4thirty Build
Post by: cheets on October 23, 2014, 11:28:40 PM
nice one Paul you so much better at doing the wright ups than me think that will be sone ting els i will be looking at doing but its ok Lee and Wizard it wont be soon so no biding up from me  :)
Title: Re: Paul's 4thirty Build
Post by: Wizard on October 23, 2014, 11:30:05 PM
Lee, they are all yours. Im keepin my standard Mr2 steering wheel as I dont want to lose my airbags.  Will just change the toyota badge to a ferrari one and I'm done.
Title: Re: Paul's 4thirty Build
Post by: Phils99 on October 24, 2014, 07:53:58 AM
yea guys defo get the 430 wheel as the LEDs work and the switch clicks nicely through all of the settings.

I did try to get the correct LED to light up at the correct setting, but couldn't be bothered with it in the end as any combination of positive and negative battery across the LED wires didn't seem to light the individual LED's up, but I found 2 wires that lights them all up when connected to 12v so I will use those.

I have a write up here http://www.dnaoc.co.uk/index.php/topic,3264.msg32655.html#msg32655 (http://www.dnaoc.co.uk/index.php/topic,3264.msg32655.html#msg32655) but it doesn't detail wiring as yet.

I also plan to countersink my start button lower as per the racing wheel and original car, this will mean bonding it from the rear or I may figure out a bracket to hold it in the steering wheel cowel. You cannot use the racing wheel start button for your can as its very plasticy!.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 30, 2014, 09:56:51 PM
So last weekend I put the steering wheel all back together and re-installed into the car

You may remember I had some rubber bits to line the edge of the steering wheel cowl. Well I had to trim these away to make some more space for the Manettino switch and starter button. Nothing major. Trimmed parts are arrowed below

(http://i1315.photobucket.com/albums/t597/pjlucas1/5_zpse0fb2a09.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/5_zpse0fb2a09.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/6_zps940d0432.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/6_zps940d0432.jpg.html)


Then I taped off the Manettino power wire as I no longer need it!  :'( :'(

(http://i1315.photobucket.com/albums/t597/pjlucas1/7_zpsaea7b565.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/7_zpsaea7b565.jpg.html)


Connected up the starter button and then gently eased the silver face plate back onto the wheel, ensuring the horn wires were poking through, and then added back the fake airbag plate

(http://i1315.photobucket.com/albums/t597/pjlucas1/8_zps030062bb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/8_zps030062bb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/9_zpsd9731330.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/9_zpsd9731330.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/10_zps4292e2cf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/10_zps4292e2cf.jpg.html)


Finished

(http://i1315.photobucket.com/albums/t597/pjlucas1/14_zps39f59c5e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/14_zps39f59c5e.jpg.html)


Took the car out and took some better photos

(http://i1315.photobucket.com/albums/t597/pjlucas1/16_zps373f91c2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/16_zps373f91c2.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/17_zps962dfe40.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/17_zps962dfe40.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/19_zps5278564a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/19_zps5278564a.jpg.html)


While it was out I gave the car a quick clean - the wheels were quite bad, so now it is all ready for Brands Hatch!!

(http://i1315.photobucket.com/albums/t597/pjlucas1/1_zps158025c9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/1_zps158025c9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/3_zps1753f300.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/3_zps1753f300.jpg.html)


And finally, in today's throw-away society you'll be pleased to know the Xbox gaming wheel has been reused. My daughters are now playing Ferrari's in their play room... ;D ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/4_zpsf5741e63.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/4_zpsf5741e63.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Phils99 on October 30, 2014, 10:36:10 PM
Almost there....you just need the dash and airvents now ;-)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 30, 2014, 10:41:53 PM
I know matey. I really hate the MR2 air vents. I'm weakening by the day.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 01, 2014, 06:50:11 PM
Here's a little video of the starter button and manettino switch in action

https://www.youtube.com/watch?v=sUCTH6QOUdE&list=UUhEAgdqSrdd8pBVdFi7pU6Q

Title: Re: Paul's 4thirty Build
Post by: ghall164 on November 02, 2014, 12:51:14 PM
 :) love all the little details well done paul you've really gone the extra mile :D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 06, 2014, 11:14:12 PM
I've been working on something the past 2 nights that I'm sure a few of you guys will like. I'll update exactly how I did it all at the weekend, but for now (as I couldn't wait) here are some pictures on my engine bay light!  ;D

When you've spent all that time working on the dummy engine you want to show it off at night as well as during the day! 
Title: Re: Paul's 4thirty Build
Post by: Lee22 on November 06, 2014, 11:47:04 PM
.
Title: Re: Paul's 4thirty Build
Post by: seriph on November 07, 2014, 09:20:08 AM
that's some cool sh1t right there dude
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 07, 2014, 10:51:13 AM
cheers Guys - it was a very simple yet effective mod.
Title: Re: Paul's 4thirty Build
Post by: Wizard on November 07, 2014, 12:30:02 PM
That's the brilliant thing about your build thread, you find simple solutions to lot of problems (ie battery cover, speaker covers, anderson clips etc). Keep up the excellent write ups.

Ps we are no longer happy with photos of "how to do it", we all now need more YouTube videos. We love em.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 09, 2014, 07:39:27 PM
Engine Bay Light

As promised here is exactly how I got the light in the engine bay

Removed the dummy engine, so I could get below the exhaust plate and to the number plate lights.

(http://i1315.photobucket.com/albums/t597/pjlucas1/n_zps5e319b23.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/n_zps5e319b23.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/p_zpsd58d3ea2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/p_zpsd58d3ea2.jpg.html)


Spliced into the number plate light wires and ran a live and an earth wire off it. Wrapped it all up in amalgamation tape

(http://i1315.photobucket.com/albums/t597/pjlucas1/s_zps10ec497e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/s_zps10ec497e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/t_zps356a1df0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/t_zps356a1df0.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/u_zpscbe13f9e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/u_zpscbe13f9e.jpg.html)


I planned to thread the spliced wire though the existing hole I had I the rear clip for the 3rd brake light

(http://i1315.photobucket.com/albums/t597/pjlucas1/o_zps911e143a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/o_zps911e143a.jpg.html)

I made the LED strip light connectable so I could change it if need be without having to redo/get to the number plate light wiring again

(http://i1315.photobucket.com/albums/t597/pjlucas1/w_zpsba093193.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/w_zpsba093193.jpg.html)


I then positioned the LED on the metal frame – they come with self-adhesive strips

(http://i1315.photobucket.com/albums/t597/pjlucas1/a2_zps8e938f9f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/a2_zps8e938f9f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/ac_zps13c3ab31.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/ac_zps13c3ab31.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/aa1_zps110ddc51.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/aa1_zps110ddc51.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/aa2_zps6d267e40.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/aa2_zps6d267e40.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/aa3_zps8108782c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/aa3_zps8108782c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/aa4_zps8c1e368d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/aa4_zps8c1e368d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/aa5_zpsb2d2df61.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/aa5_zpsb2d2df61.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 09, 2014, 09:50:50 PM
I've also been doing a few other bits and bobs to my car.

I made some engine cover pates. I nicked with idea off V8 KLR to hide the gap I have here

(http://i1315.photobucket.com/albums/t597/pjlucas1/a_zps13a40486.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/a_zps13a40486.jpg.html)


I made a template out of cardboard, then cut out of plastic, put heat refelctive tape on one side, covered in CF style wrap the other and then stuck some magnets on the underside so it sticks to the metal on the car in place...

(http://i1315.photobucket.com/albums/t597/pjlucas1/b_zps530a6899.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/b_zps530a6899.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/c_zps4b39209d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/c_zps4b39209d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/d_zpscee7f750.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/d_zpscee7f750.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/e_zps10a56421.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/e_zps10a56421.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/f_zpsfe7d897c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/f_zpsfe7d897c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/g_zps8eebe250.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/g_zps8eebe250.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/h_zps92bb9893.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/h_zps92bb9893.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 09, 2014, 09:53:17 PM
Also I didn't like the rough edge along this part of the rear deck, so I got some black plastic angle and stuck this over to create a nice neat edge

(http://i1315.photobucket.com/albums/t597/pjlucas1/k_zps1f2032db.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/k_zps1f2032db.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/l_zps16db4abd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/l_zps16db4abd.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/z_zps2fe85d6b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/z_zps2fe85d6b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/x_zpse52b0e39.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/x_zpse52b0e39.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/a1_zps296dd177.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/a1_zps296dd177.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 09, 2014, 09:59:41 PM
Then I went a bit crazy with the CF wrap I had and covered a few more things...

Rear fuse box cover

(http://i1315.photobucket.com/albums/t597/pjlucas1/i_zpsff66143a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/i_zpsff66143a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/m_zpsc822bb1a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/m_zpsc822bb1a.jpg.html)


Fuse box in place along with the also covered rear alarm trigger holder

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo4_zps9ffa5c84.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo4_zps9ffa5c84.jpg.html)


Front fuse box cover

(http://i1315.photobucket.com/albums/t597/pjlucas1/bb1_zps5d262bb1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/bb1_zps5d262bb1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/bb2_zps129fc647.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/bb2_zps129fc647.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/bb3_zpsaedfa17b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/bb3_zpsaedfa17b.jpg.html)


3rd Brake light flasher box also done

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo1_zps37038e25.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo1_zps37038e25.jpg.html)


Here are both engine cover plates in place

(http://i1315.photobucket.com/albums/t597/pjlucas1/photo3_zpsd2b71475.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/photo3_zpsd2b71475.jpg.html)


Title: Re: Paul's 4thirty Build
Post by: beemaman on November 09, 2014, 10:08:23 PM
Great work Paul ive got a massive roll of carbon sheet at work.may use some after seeing your great work :) really looking good buddy :)
Title: Re: Paul's 4thirty Build
Post by: Furrari on November 09, 2014, 11:21:26 PM
Neither the CF wrap that you have used nor the CF dip that I have used look a lot like real CF but they still look good.  Infact the dip I have used is the least like CF I have seen in the available dips.  So why use it?  Cos it looks good.
Title: Re: Paul's 4thirty Build
Post by: cheets on November 10, 2014, 12:05:28 AM
Nice ruches Paul
Title: Re: Paul's 4thirty Build
Post by: CdRsKuLL on November 10, 2014, 01:22:27 PM
Love the LED's fella :-) I did something similar back in old 2007, however the fake engine wasn't around in them days :-)

http://www.dnaoc.co.uk/index.php/topic,12.msg229.html#msg229

O, and mine were red!

It's the little touches like these that make the car your own.

Steve
Title: Re: Paul's 4thirty Build
Post by: ghall164 on November 10, 2014, 08:23:51 PM
 :D great job as allways Paul love all your mods your car is a real work of art you and dad have worked so hard on her and it shows
Title: Re: Paul's 4thirty Build
Post by: FBP3rd on November 10, 2014, 09:40:01 PM
bloody hell steve (cdr) 2007.Daz :o
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 07, 2014, 06:13:44 PM
Oh how I do miss posting my regular weekend build updates.  :'( Haven't done one for a while, but here's is a little mod I've done. A paint code sticker!!! Cheers to Lee for sorting them out.
Title: Re: Paul's 4thirty Build
Post by: Ronan7051 on December 08, 2014, 11:15:38 PM
Oh how I do miss posting my regular weekend build updates.  :'( Haven't done one for a while, but here's is a little mod I've done. A paint code sticker!!! Cheers to Lee for sorting them out.

Class Paul ,it's looking really good, a credit to you .
Title: Re: Paul's 4thirty Build
Post by: Lee22 on December 09, 2014, 10:15:58 PM
Looks just the job Paul...

Glad it turned ok mate  ;D

Lee
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 10, 2014, 10:16:55 PM
had a chat with woodsport this week and pleased to report the car is booked in for start of January.  ;D. That's it! Can't wait.
Title: Re: Paul's 4thirty Build
Post by: Lee22 on December 10, 2014, 10:42:39 PM
Fingers crossed it doesn't snow Paul..... ::)
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on December 10, 2014, 10:54:48 PM
Paul,
Your life will change forever.
It will be a totally different car and will put an even bigger smile on your face every time you drive it.
Well done mate.
Title: Re: Paul's 4thirty Build
Post by: Wizard on December 11, 2014, 07:38:15 AM
Wow. It will certainly be a fantastic start to the new year for you. I followed rudy home from madmans. The acceleration of Rudy's car was very impressive.
Title: Re: Paul's 4thirty Build
Post by: kalifornia on December 11, 2014, 08:51:53 AM
What engine is going in there 3VFZ or the 2GR ?  Both very impressive
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 11, 2014, 11:43:14 AM
the Lexus RX300 one - the 3VFZ which is the same as Rudy's and V8 KLR's. I have been told the 2GR is just a bit too much of an animal  :o
Title: Re: Paul's 4thirty Build
Post by: ghall164 on December 11, 2014, 03:47:51 PM
 ;D all the looks and now the power to so pleased for you paul it's one hell of a motor you've worked hard for your dream car  :)
Title: Re: Paul's 4thirty Build
Post by: V8 KLR on December 11, 2014, 07:50:29 PM
NICE - just think... more NOISE... more SPEED.. we can go for a burn up together.... ::)
Title: Re: Paul's 4thirty Build
Post by: ferrari feb 14 on December 13, 2014, 05:54:56 PM
Great news Paul  :) looking forward to a visit , all the best for Christmas and we no you will hav a gud new year with that engine lol.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 20, 2014, 09:48:46 AM
Well as the car goes away very soon I thought I’d start cracking on redoing the dummy engine. There’s no point taking it up to Woodsport with the dummy engine as it will just get in the way and I can do the modifications to it while the car is away.

Dummy Engine Cover – V6 Conversion

I have had a look at Rudy’s and V8 KLR’s covers in the flesh and the issue we have with the standard cover and the V6,  is that parts of the real engine are higher than the standard MR2 and thus the dummy engine would foul parts of the real engine. The main areas that need cutting back are the centre pipe section and also where the metal side bars are. The metal side bars need raising up and unfortunately with my plans I won’t be able to have the diagonal pieces of metal either. I also plans to use proper maff pipes and hoses and make the centre section clear the V6 this way as oppose to cut cutting back the fibre-glass on the dummy.

My plan is to also reduce down the side of the “walls” of the dummy engine so it is less box-like and thus more frame like that just literally goes over the top of the V6. There is plenty of real engine going to be seen through the frame like cover anyway.  This will also help with letting heat out through the rear deck grills.

So I remove the engine last Sunday and set about taking it all apart.  So here what was left – the bare shell:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3781_zps2bee1e19.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3781_zps2bee1e19.jpg.html)

The side parts at the yellow arrow will be cut back as will the areas at the blue arrows. The new metal side pieces will run along the yellow line and I will cut back the area in red to allow the heat to escape.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3780_zps79eb3f9d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3780_zps79eb3f9d.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: V8 KLR on December 20, 2014, 01:06:07 PM
Go on.....cut it all up..... ;D...if you need any help I LOVE cutting things up..... ::)
Title: Re: Paul's 4thirty Build
Post by: Wizard on December 20, 2014, 04:25:37 PM
Is woodsport going to do a build thread on your engine??
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 21, 2014, 08:30:37 AM
Is woodsport going to do a build thread on your engine??

it hasn't been discussed tbh. Woodsport did detailed ones on Beany's and Rudy's so I'm not sure if it is worth Paul taking time over it. Hopefully he'll take a few pictures for me and send them on as it progresses. I'll then add them to this thread instead  ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 21, 2014, 02:31:30 PM
I’ve purchased a real power steering pump that I plan to use

(http://i1315.photobucket.com/albums/t597/pjlucas1/img_3801_zpsd83edd5c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/img_3801_zpsd83edd5c.jpg.html)


So here are some more demolition pictures. I’ve cut away completely the lower parts of the pipes etc..

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3793_zps195264ee.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3793_zps195264ee.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3794_zps4e827913.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3794_zps4e827913.jpg.html)

Fake maffs cut out

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3795_zps6940cb74.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3795_zps6940cb74.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3796_zpsa4122efb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3796_zpsa4122efb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3797_zps5e8a0831.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3797_zps5e8a0831.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3798_zps582382f1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3798_zps582382f1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3799_zps507cba5c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3799_zps507cba5c.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 21, 2014, 02:43:50 PM
So the plan is to replace the gap I have created with real maffs/pipes etc.. I’ve purchased 2 second hand ones from a Ford Puma – the below is the sort of thing I mean

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3800_zps75e251d2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3800_zps75e251d2.jpg.html)


Here I have added the rubber pipes at either end

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3809_zps13841c5e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3809_zps13841c5e.jpg.html)


I’ve had a long think about the best way to attach the whole new set up to the original engine. What I think will work best is if the real maffs/pipes are attached to tin cans and then bond the whole set-up to the underside of the original engine pipe areas. (see arrows below) The tin cans will be panted black to blend in with the original dummy engine.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3811_zps1be64139.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3811_zps1be64139.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3813_zps8741ed1f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3813_zps8741ed1f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/FullSizeRender_zpsa131395a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/FullSizeRender_zpsa131395a.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Furrari on December 21, 2014, 03:06:46 PM
You're a brave man cutting all that away.  I know it'll look good when it's finished but it frightens me.
Title: Re: Paul's 4thirty Build
Post by: MADMAN on December 21, 2014, 03:15:52 PM
It,s good when a plan comes together, great work Paul.
MADMAN 8)
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on December 21, 2014, 07:43:31 PM
Great work mate.  :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 21, 2014, 08:02:35 PM
thanks for all the comments guys  ;D

yes Mick, there were instances this week when I thought "OMG - what have I done?" lol. but it is something that needs to be done I'm afraid and it will be fine once done.

I probably wont have as many wires/tubes (scart and aerial leads!) as before, but they'll be more real ones underneath anyhow.

tbh i didn't think I'd even touch it until after the car was gone but temptation got the better of me. still, i was going to do some work on it today but it doesn't make sense to at the moment - i'd be working in the cold outside. might as well wait until i have a nice clear (warmish) garage to do it and then i can take my time with it. let's face it - i'll have some time to get it done!
Title: Re: Paul's 4thirty Build
Post by: ghall164 on December 22, 2014, 09:04:43 AM
You can't fix the patient with out opening them up first. I have know doubt this is going to look awesome well done paul it takes balls to rip apart something that to everyone else looks great to make look even better it's all these little extras that make the car your own cant wait to see the end results
Title: Re: Paul's 4thirty Build
Post by: V8 KLR on December 22, 2014, 11:25:04 AM
Hello Paul looks good...you will have to grind away the underside of one of the MAFS (right hand one) as it sits right on top of the inlet plenum...you will find that out when you sit the cover back onto the V6. You will also have to cut - literally - right through the right hand side of the cover as again the V6 is in the way...but it is possible to run a strip of material whatever you plan to use, as you know I used aluminium , to bridge the gap and thus provide rigidity...if you trim the inside lip of the rubber pipes they fit onto the MAFS a whole lot better you can really get them right on...hope that helps M8.. ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 22, 2014, 11:15:11 PM
Cheers Andy. Thanks for the tips. I knew about the right hand side of the cover but not about trimming the underside of one of the maffs. Maybe I could bring my cover over in February and try it on your to check on clearances etc.  ;)
Title: Re: Paul's 4thirty Build
Post by: V8 KLR on December 24, 2014, 11:21:57 AM
No problem at all M8...
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 05, 2015, 07:41:34 PM
Well people – I am now car-less for a while. The car was dropped safely off at Woodsport the other day.

The trip up was long – 4.5 hours each way but the 430 didn’t miss a beat. We left at 6am in the pitch black and it was absolutely hammering it down with rain. It was quite scary. But as we went further north the weather eased and the drive was really enjoyable. That is the furthest I have driven the car in one go and I must say I was expecting to have a bad back at the end of it, but all was fine which really pleased me.

Around half-way we met up with Lee22 (I had a PlayStation driving wheel to give him – another thing for his to do list!) – was nice to meet him and show him around the car. I think he liked what he saw despite the car being absolutely filthy.

We arrived at Woodsport around 11am – as the security guard said, you can’t miss it as there are MR2s everywhere!  Me being me, I had a big list of things to do through, but as I had been told, Paul really knows his stuff and had it all covered anyway. I was concerned that the car being so dirty, I didn’t want it left dirty all that time, but Paul has all the cleaning gear and will get it cleaned Monday before work commences. What great service.  ;D

We spent around an hour going through everything. The engine is well on the way to be being fully assembled – it looks amazing. I just need to decide on the colour scheme for the cam covers, plenum etc.. these are already primed and awaiting paint! Exhaust system will be done in stainless-steel with the normal tail pipes. Paul really recommends the 5th gear-extension as well so I am going for that. Another thing we are going to do is move the car battery to the frunk. I didn’t think this was an option but I am really glad we are going down this route. I will lose a bit of room in the frunk, but not a lot to be honest, plus it mean charging the car is easier as I can access it through the front bonnet – so no more scrambling through the rear-number plate hole to the Anderson clamp.

So after leaving Woodsport we called in at JD’s house who I have gotten to know well in recent months and met at Donnington.  He is building an Extreme 360. It was lovely to see his car in the flesh and hear it. It looks and sounds great. Great hospitality - thanks for the coffee and Christmas cake JD! Then it was the small matter of the drive home, which was fine in the end.

So this is my garage now   :'( :'( :'(

(http://i1315.photobucket.com/albums/t597/pjlucas1/garage_zpsd307669b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/garage_zpsd307669b.jpg.html)

Here is a short film of me driving up there  ;D

https://www.youtube.com/watch?v=RQkWFzq5gqs&feature=youtu.be

So now I have some garage space, I can crack on with the rebuilding of the dummy engine. Shame it is just so cold these days!!! Brrr. 
Title: Re: Paul's 4thirty Build
Post by: Wizard on January 05, 2015, 09:33:07 PM
Paul. The car is gonna be amazing. I was following Rudy home a few month ago and he put his foot down, the sound is stunning.

Woodsport is considered as the King of MR2 conversion and he quality is always fantastic
Title: Re: Paul's 4thirty Build
Post by: Phils99 on January 05, 2015, 09:35:48 PM
you big southern softie.....get in the garage, I have just been in mine tonight...in my SHORTS!! honest!...it was cold though!
Title: Re: Paul's 4thirty Build
Post by: paulcas on January 05, 2015, 10:37:18 PM
Hi Paul,
exciting times ahead buddy. Once the conversion is completed you'll be over the moon with the difference.

Regards
paulcas
Title: Re: Paul's 4thirty Build
Post by: Lee22 on January 05, 2015, 11:12:58 PM
Hi Paul,

Great o meet you Saturday morning, just a shame it was so cold.
A million thanks for getting the gaming wheel to me, that's a real help  ;)

The car looked fantastic and I picked up a couple of little pointers too..... ;D

Glad you made it to wood sport and back home mate...!

Isn't it strange looking into the garage and not seeing anything in there :(

Lee
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 11, 2015, 07:11:54 PM
Right the car has been away for a week, so I thought I’d get stuck into the engine cover. Prepared to be a bit shocked everyone! LOL  :o :o :o

I continued to cut away a lot from around engine box area leaving much more of a frame like structure


(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3877_zps79074592.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3877_zps79074592.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3878_zpse94081cb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3878_zpse94081cb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3879_zps0cc77e95.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3879_zps0cc77e95.jpg.html)


I know it looks drastic but this was all part of the plan.  ::) Next was to add some strength back into the side parts. I did this by screwing into the gaps, wooden batons which made the whole structure rigid again.  These pieces of wood will be painted black and then covered in metal.


(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3881_zpsda7de5ce.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3881_zpsda7de5ce.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3882_zps95659bbe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3882_zps95659bbe.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3883_zps1e17c3cf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3883_zps1e17c3cf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3884_zps23f91f39.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3884_zps23f91f39.jpg.html)


It is now nice and solid again.  ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 11, 2015, 07:20:20 PM
Next after chatting with Andy I redesigned my Maff/Pipe set up to try and avoid the maffs actually sitting on the V6 engine plenum. For each pipe I use 3 tin cans (I’ve been eating a lot of baked beans lately!)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3894_zps92493b60.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3894_zps92493b60.jpg.html)


Maffs with pipe sections

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3895_zps18079046.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3895_zps18079046.jpg.html)


This is how each side fits together. Once I am happy with the whole set up and everything is painted, the pieces will all be bonded together and the installed into the engine frame. The cans arrowed on each side will be bonded to the underside of the original engine part.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3898_zpsc4ba17a7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3898_zpsc4ba17a7.jpg.html)


So for now it is all stuck in place with tape. The only actual tin can that will be on view is arrowed below, and this will be painted satin black.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3899_zps9881a68f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3899_zps9881a68f.jpg.html)


Here is the view from the other side

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3900_zps893f44b4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3900_zps893f44b4.jpg.html)


I even added a nice shiny new hose clips to see the real effect - loving it

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3901_zpsa2965964.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3901_zpsa2965964.jpg.html)


And then added the black maff sensor

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3902_zps10954aa4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3902_zps10954aa4.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 11, 2015, 07:32:43 PM
Next, I’ve been thinking about what to do in the middle section. I had cut away the base area when I did version one and replaced it with a grill but this is not an option now. I am not worried about hiding what’s underneath now but wanted to fill the gap with something.

I did plan to install both the power steering pump plus another item that can utilise the silver Ferrari cap, but the more I thought about it the more I thought there was no need for both. I can always change things here at a later date once the car is back but for now I plan to do the following:

The power steering pump came with a nice bracket which I thought I’d use again and attach to the rear part of the engine. Hard to explain but pictures say it all

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3906_zps0f2d573a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3906_zps0f2d573a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3907_zpsd78670f0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3907_zpsd78670f0.jpg.html)

This bracket is just in place with an Allen bolt and I can trim the underside of the pot should I have clearance issues. The offset round circle parts at the front of the pot I plan to have some pipes coming out of them and going towards the front of the engine, so this will cover part of the gap in the middle anyway. I’ll have 3 pipes going along there which will be enough.
Title: Re: Paul's 4thirty Build
Post by: Wizard on January 11, 2015, 07:59:00 PM
Wow. In more excited about your dummy engine that the V6. Looks absolutely stunning. 
Title: Re: Paul's 4thirty Build
Post by: Lee22 on January 11, 2015, 09:00:12 PM
Looking good mate... Looking good.... :D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 11, 2015, 09:08:27 PM
So next was to trim away yet more of the engine to neaten things up. I focused on the circled areas below getting them all flush, removing any remains of it being a box like structure to start with

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3908_zps180b7cd8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3908_zps180b7cd8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3909_zps04cc3bf2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3909_zps04cc3bf2.jpg.html)

Also trimmed back the lower part of the air boxes as well – see arrow below

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3910_zps0ab594e3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3910_zps0ab594e3.jpg.html)


Then it was time to fit up the metal work – I had made a template out of cardboard previously and was just a case of copying onto the aluminium

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3911_zps1fef9d6f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3911_zps1fef9d6f.jpg.html)


The metal just covers the wood perfectly from the inside

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3912_zps21538c1e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3912_zps21538c1e.jpg.html)


And trimmed it so the metal goes further along the top at the front of the engine

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3913_zps9c053a55.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3913_zps9c053a55.jpg.html)


The metal is then bolted through the wood to the engine cover via allen bolts

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3914_zps28128abb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3914_zps28128abb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3915_zps9ed2b727.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3915_zps9ed2b727.jpg.html)


Finally the front bolt will be longer as it is here I can attach the strings that lift the cover up when you raise the rear deck

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3916_zpsd7246ef7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3916_zpsd7246ef7.jpg.html)


So now during the week I may do a spot of filling and sanding and rubbing down on the cover to gets some imperfections out and then next Saturday (weather permitting) I will mock it all up properly and try out on Andy's V8 KLR to see how it looks/clears etc.. then all being well I will get on with priming and painting and the rest of the detailing (pipes etc..). Thats the plan anyway!  ;)
Title: Re: Paul's 4thirty Build
Post by: ferrari feb 14 on January 11, 2015, 09:50:36 PM
Great work Paul as always its good you can check it on another car so it's ready for your car soon as it's back, hope you call in after you hav picked it up cheers jd
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 12, 2015, 08:02:53 PM
Yeah I'm very lucky I've got V8 KLR to test it on. Yeah hopefully should be able to call in on way the home. Most likely it will be a Friday.
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on January 12, 2015, 09:36:33 PM
Credit to you mate.
All I can say is well done and you're very brave  :)
Title: Re: Paul's 4thirty Build
Post by: V8 KLR on January 13, 2015, 01:15:53 PM
Got my hacksaw ready.............. :o
Title: Re: Paul's 4thirty Build
Post by: MADMAN on January 13, 2015, 03:22:41 PM
Got my hacksaw ready.............. :o


Throw your hacksaw away, the Angle grinder is much better ;D
Looking great Paul I like your commitment 8)
MADMAN 8)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 15, 2015, 10:39:44 PM
So done a bit of work this week on prepping the cover, filling and sanding and then I mocked it all up for it's dress rehearsal on sat.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 16, 2015, 10:09:33 PM
V6 update. Engine is fully built and painted and gearbox is also ready. Next week the car goes on the ramp and its out with the old and in with the new  ;D
Title: Re: Paul's 4thirty Build
Post by: Wizard on January 17, 2015, 12:06:43 AM
Progress certainly is quick. I bet you can't stop smiling when you think about your car. It's will totally transform the drive. And yes, I'm jelaous.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 17, 2015, 07:56:39 AM
Yep Ranj, that certainly is the plan - everyone tells me how great the conversion is. Was looking on the TwoBrutal forum last night and there's a whole section dedicated to WoodSport builds. He's be doing it for years. So I am definitely happy I have taken it to the right place!  :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 18, 2015, 08:48:48 AM
So yesterday I took the engine cover over to Andy’s to try it out on his V6.  (Big thanks to Andy for letting me do this.)  It basically fits but there needs to be a little tweaking. The bracket at the rear of the engine is a non-starter as they isn’t enough room for it to sit flat, so I would need to change that. Plus in the below pictures the pot with the yellow Ferrari badge is fixed to the real V6 so I’d probably look to do something there once the car is back.

So here is the engine cover in place.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6163_zps1dca5764.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6163_zps1dca5764.jpg.html)

I had added some Allen bolts along the Aluminium strips and as luck would have it, this one was right in the way on part of the Plenum – so I removed it and the engine cover fitted. But I still don’t have much adjustment room left and right. So will look to ways to give me more adjustment room.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6164_zps85384dd2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6164_zps85384dd2.jpg.html)

Arrowed is the bracket that won’t work now.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6165_zps44a5bc8c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6165_zps44a5bc8c.jpg.html)

Other photos

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6166_zps5910e6e8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6166_zps5910e6e8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6168_zps9d390755.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6168_zps9d390755.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6169_zps80736300.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6169_zps80736300.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6170_zps01af4023.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6170_zps01af4023.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6171_zps1bf5c748.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6171_zps1bf5c748.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6172_zps2402ec73.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6172_zps2402ec73.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6173_zps328f49be.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6173_zps328f49be.jpg.html)

Once I got home I solved the Aluminium strip issues easily. I took one side apart, and then put the pieces of wood on the outside of the original engine frame, and then recovered with the metal. This has the effect of widening the side parts by around 2cm so I will have much more adjustment room! Happy days

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6156_zpse4cf99d1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6156_zpse4cf99d1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6157_zps0736057f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6157_zps0736057f.jpg.html)

Now I can start prepping and painting it up.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 24, 2015, 07:09:49 AM
I started to paint up the maffs/sort the pipes out this week. I used silver alloy wheel paint for the maffs and they have come up a treat. I gave all the rubber pipes a good clean and then sprayed up all the tins cans as well. I then bonded the cans into the maffs and rubber tubes using StikaFex, so they are now secure. Each pipe does still come apart in the middle in the section where there is a big jubilee clip just in case I need to separate the two or do any fine adjustment.  Finally I tested it on the engine cover.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3958_zps0831e559.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3958_zps0831e559.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3959_zpsd6169c10.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3959_zpsd6169c10.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3961_zps3bc2871a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3961_zps3bc2871a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3963_zps02e46564.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3963_zps02e46564.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3964_zps72269927.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3964_zps72269927.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3966_zps2eefdedf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3966_zps2eefdedf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3969_zps8b1dcece.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3969_zps8b1dcece.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3971_zps36d1313e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3971_zps36d1313e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3972_zps80de6af2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3972_zps80de6af2.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Furrari on January 24, 2015, 11:52:36 AM
Impressive work.
Title: Re: Paul's 4thirty Build
Post by: cheets on January 25, 2015, 05:14:50 PM
its looking good Paul think i will be doing somthing similar  wen i get ronde to it :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 25, 2015, 07:59:37 PM
***WARNING***

The following images may cause distress to some viewers!! LOL

Last Sunday ended on a bit of a downer as I had a bit of an accident with the engine cover! Doh!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3943_zpsb95f47f0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3943_zpsb95f47f0.jpg.html)

So I had no choice but to cut the rest of the bits off and end up with 2 separate pieces. However I had the pieces of wood and I knew that they fitted perfectly between the 2 fibre glass pieces so I knew what the measurements should be once I thought of a way to re do it all.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3945_zpse841fc0b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3945_zpse841fc0b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3946_zps97a04120.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3946_zps97a04120.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3947_zps2021c762.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3947_zps2021c762.jpg.html)


So this is what I was left with:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3973_zps5e1f6d2c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3973_zps5e1f6d2c.jpg.html)

But I wasn’t going to let something like this beat me! So after some thought I came up with the solution! I would use the actual alloy strips to connect the front and back pieces together with the help of L-shaped bracket and the holes already in the Alloy strips. I ordered these brackets from Toolstation. I chose these because I like the fact there were 2 large gaps on each side which would be perfect for adjustment and fine tuning the shape of the whole set up.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3953_zpse051e0fe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3953_zpse051e0fe.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3954_zps7ac82796.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3954_zps7ac82796.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3955_zpse51f5fbb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3955_zpse51f5fbb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3956_zpsbbe77c8b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3956_zpsbbe77c8b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3957_zpsb0ac1a5c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3957_zpsb0ac1a5c.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: ghall164 on January 25, 2015, 08:13:19 PM
Nicely done as usual paul this car Is constantly improving bet you can't wait to feel the engine improvement she's a lovely motor
Title: Re: Paul's 4thirty Build
Post by: Spacecowboy on January 25, 2015, 08:48:53 PM
Not entirely sure what what wrong here but glad you found a solution
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 25, 2015, 09:49:55 PM
So this Saturday I set about fixing it all. The L-shaped brackets on the front part I had to cut away a bit of a slope. This is because I had designed it so the alloy strips sloped downwards towards the back of the car, so this was done to allow this to happen. I drilled holes in the fibre glass and then bolted it all up and managed to get it all back to how it should be.

The frame is strong enough for what it is meant to do, and also once the pipes in the middle are boned in all with be fine. I will still have it lifting up with the rear deck on strings once it is back in the car.

I have also filled down this lip on the advice of Andy because with the V6 the roof when folded down might sit slightly higher than before thus I don’t want this lip that was on here to foul and stop the deck closing properly

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3974_zpsfe9c02cf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3974_zpsfe9c02cf.jpg.html)

Here is the bracket set up. I used large nuts as spacers to get the position of the alloy strips just right. I have also since tidied up the slopes on the front brackets so they look a little nicer.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3976_zpsa92586ca.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3976_zpsa92586ca.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3977_zps981a01d3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3977_zps981a01d3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3978_zps0bdf4af5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3978_zps0bdf4af5.jpg.html)

Time for bed!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3979_zps219aea8b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3979_zps219aea8b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3980_zps2fbc7eae.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3980_zps2fbc7eae.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3981_zps988a6d1c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3981_zps988a6d1c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3982_zps57d70203.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3982_zps57d70203.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3983_zps22d1bee7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3983_zps22d1bee7.jpg.html)

So next I unbolted it all and set about priming it all up.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3984_zpsa3717539.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3984_zpsa3717539.jpg.html)


Painted up the maff sensor parts are they were looking a little tired

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3988_zpsd6d63eee.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3988_zpsd6d63eee.jpg.html)


Rear part done in satin black

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3989_zps77e3c307.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3989_zps77e3c307.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3990_zpsf0009f73.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3990_zpsf0009f73.jpg.html)


Masked up and painted the plenums

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3993_zps224993ac.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3993_zps224993ac.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3994_zps9baf6e9c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3994_zps9baf6e9c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3995_zps7085be53.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3995_zps7085be53.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_3996_zpsed1e142d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_3996_zpsed1e142d.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Furrari on January 25, 2015, 10:57:14 PM
I think I would have been looking for a rope and and an overhead beam by this point.
Title: Re: Paul's 4thirty Build
Post by: cheets on January 25, 2015, 11:16:57 PM
well wen i sed something similar was not thinking that drastic  :D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 01, 2015, 07:20:52 AM
More bits and bobs on the engine cover. Finally got all the bits painted and started to reassemble it all back. Thankfully the metal bars holding it all together, work well and it is nice and sturdy again.  Also added back some of the Allen-bolts and washers to the plenums

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4009_zpsa2026ab3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4009_zpsa2026ab3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4010_zpsc1652b7e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4010_zpsc1652b7e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4019_zpsc2f8190c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4019_zpsc2f8190c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4020_zps8786c393.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4020_zps8786c393.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4022_zps561150bd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4022_zps561150bd.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4023_zpse9dfa4b5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4023_zpse9dfa4b5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4024_zpseb0502cf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4024_zpseb0502cf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4030_zps1d75f06c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4030_zps1d75f06c.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4025_zps60a55983.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4025_zps60a55983.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4031_zps8b16adfd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4031_zps8b16adfd.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 01, 2015, 07:24:47 AM
So next was the moment of truth and time to bond the pipes and maffs to the cover. I turned the cover upside down, etched all the various areas and then bonded it all in place, using spare hose clips to act as clamps. I also made some connectors for the maffs sensors out of old cables I had used previously as well. I then left it to dry overnight.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4036_zps7af1d9ba.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4036_zps7af1d9ba.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4037_zps526a679f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4037_zps526a679f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4038_zps751b83e6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4038_zps751b83e6.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4040_zps6984ea9e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4040_zps6984ea9e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4039_zps1e8b1b8b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4039_zps1e8b1b8b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4041_zps16d86cb9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4041_zps16d86cb9.jpg.html)

Will do some more work on it today… ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 02, 2015, 10:00:26 PM
More progress pictures. Added some hoses and the maff sensors
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 03, 2015, 10:01:19 PM
I was going to leave the middle section clear but wanted to use the bmw power steering pump I had bought. I knew it would be too deep do I trimmed the bottom off it and then bolted it to the back with a black packer boot so it looks like a tube.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 03, 2015, 10:06:22 PM
Added so more hoses down the middle and use some p clips to keep them in place
Title: Re: Paul's 4thirty Build
Post by: Lee22 on February 03, 2015, 10:54:10 PM
So when you going into business building these for all other members Paul..??  ;)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 03, 2015, 11:07:36 PM
Started painting up the writing  ;D
Title: Re: Paul's 4thirty Build
Post by: kalifornia on February 04, 2015, 09:11:33 AM
looks fantastic
Title: Re: Paul's 4thirty Build
Post by: beemaman on February 04, 2015, 09:21:58 AM
WANT A JOB PAUL ?? looks great buddy :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 04, 2015, 07:24:08 PM
So when you going into business building these for all other members Paul..??  ;)

What, engine covers or cars? Lol. I've often thought when I retire from the city Id be happy building a few of these cars for people.  ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 04, 2015, 07:27:11 PM
WANT A JOB PAUL ?? looks great buddy :)

Haha. Thanks Wayne. That's the second time you've offered me a job! Brian at DNA also did. It is just Birmingham is just too far a commute for me! Lol.
Title: Re: Paul's 4thirty Build
Post by: paulcas on February 04, 2015, 07:44:10 PM
what a work of art - well done Paul  8) :o
Title: Re: Paul's 4thirty Build
Post by: cheets on February 05, 2015, 01:16:37 PM
looking Really good Paul can not what till i ma at that stage
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 05, 2015, 10:57:59 PM
So just painted up the horse and shield and now it is done. Can be put away for a few more weeks while I get the garage ready for the cars return.
Title: Re: Paul's 4thirty Build
Post by: MADMAN on February 06, 2015, 10:29:50 AM
First class job Paul, I bet you cant wait to get your beast back home, any news on completion date yet?
Time to clean your garage to the same standard as your car and engine cover 8)
MADMAN 8)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 06, 2015, 11:56:22 AM
Had an update from Woodsport yesterday. Everything is going to plan and there's been no issues. Completion in approximately 3-4 weeks   ;D ;D ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 13, 2015, 10:05:15 PM
So I've tidied up the garage ready for the cars return
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 13, 2015, 10:23:19 PM
Just bought this. I wonder what my  next project is?  ::)
Title: Re: Paul's 4thirty Build
Post by: Lee22 on February 13, 2015, 11:42:37 PM
Interesting Paul....

What's the thoughts mate?
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 14, 2015, 06:38:20 AM
I'm gonna have a go at making a new centre console. So got this one for £20 to chop up. Plan is to make one similar to Phils real 430 one that goes on top of the cut down mr2 one. It will have a proper handbrake gaitor and be covered in leather. Will reposition the window switches as well. If I cock it up then I still have all the original left.

Title: Re: Paul's 4thirty Build
Post by: beemaman on February 14, 2015, 09:20:35 AM
well if the console is as good as the rest of the car then ile be offering you a job for the 3rd tme buddy lol :)

whens the beast home buddy ?
Title: Re: Paul's 4thirty Build
Post by: Furrari on February 14, 2015, 11:06:38 AM
I'm  impressed with the garage never mind the car.  :-)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 14, 2015, 10:12:46 PM
Evening peeps. Didn't plan to work on this today but while was waiting for the IKEA wardrobe delivery ( don't ask!) I sneaked my tools back in the garage and made a mess again. Started by cutting down the gear lever part. My concerns here is I need to have the console low enough so I am able to pull the handbrake up so I used the lowest point as a guide. Then I cut the rear part off aswell - No more cup holders or arm rests, and then took stock.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 14, 2015, 10:31:05 PM
I added some wood the retain the shape at the rear and then made a template out of cardboard to see how it would look. Then it was off to b and q for some mdf. I was concerned I didn't want the side parts to be too wide so I got the thinnest possible. Whilst in the store I decide I would build the console via a frame like structure and then put the top part in afterwards. My plan it to bolt the wood structure to the black plastic at the end.
Title: Re: Paul's 4thirty Build
Post by: Lee22 on February 14, 2015, 10:36:21 PM
Paul,

I'm really interested in this mod your doing mate...!

I was considering buying one of these off eBay.

But just shy of £200 there is no way.


So if this one of yours comes out looking good (like everything else you do)... I'll be following suit, as I really don't like mine...  It's the only real MR2 part in the car, and I need to change it.

Lots more pictures Paul please as you continue.... ;D
Title: Re: Paul's 4thirty Build
Post by: Lee22 on February 14, 2015, 10:39:59 PM
Or...... Thinking again....

Just buy 2 of everything your buying and do 2 Paul.. And sell me the final addition when your finished.... ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 14, 2015, 11:34:32 PM
Lol Lee. I'm still not convinced it will look any good but I'll keep at it. I always said I'd try making one. Yes the mr2 one needs something doing to it defo. I do like the one you just posted but yes the cost does mount up. (Got a big bill to pay in a couple of weeks  ;D) the beauty of this is I know before I trim it in leather whether it will look any good and by then it would have cost no more than £50 in materials. I might aswell make the most of the garage space while I can.
Title: Re: Paul's 4thirty Build
Post by: cheets on February 15, 2015, 11:48:03 AM
Hi Paul looking good this is what i started doing with my centre consel
 just mocking up in timber
Title: Re: Paul's 4thirty Build
Post by: cheets on February 15, 2015, 11:51:56 AM
Next  moved the hand drake over started making it in plastic  hope this helps

Mark
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 15, 2015, 12:12:04 PM
Cheers mark. I think I'm just gonna leave it as wood and cover in leather. Should be fine
Title: Re: Paul's 4thirty Build
Post by: Furrari on February 15, 2015, 12:21:46 PM
I don't think you should post this kind of picture.  I makes me realise how inadequate my ability is.  :-)
Title: Re: Paul's 4thirty Build
Post by: Lee22 on February 15, 2015, 02:28:08 PM
It makes me realise how inadequate my ability is.  :-)

It's funny you should say that Mick, your wife says the same..!! Lol lol ;D

(Only kidding mate..!)
Lee
Title: Re: Paul's 4thirty Build
Post by: Furrari on February 15, 2015, 02:42:01 PM
You can go off some people.  :-)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 15, 2015, 05:56:18 PM
did a little more work on the centre console today. Looking at the slope at the end last night, I thought it was a little too shallow so I adjusted it to be steeper and thus follow the mr2 piece more closely. I also cut away part of the front of the mr2 part to allow the bracing wood to sit further back
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 15, 2015, 06:02:32 PM
then i took the frame off and cut out the top part of mdf and screwed it to the support slats. then all that was left to do was cut the front part to cover the slope part and it was done. I have gone as far as I can go for now without the car as i don't want to start cutting holes at the top for handbrake, storage trays, gear stick, without the car to reference. There is also the question of whether it is too wide between the seats (something that could be adjusted) but then Lee had the idea of extending the wood down to have the whole thing out of wood and do away with the mr2 part and secure it via the original fixings (arrowed in the last picture)  and then cover the whole thing in leather. I am seriously considering this but that can wait until the car is back. 
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 15, 2015, 06:26:42 PM
***Question Guys/MADMAN***

I want to fit a H-Gate like in the picture below but i believe in order for it to work I need to have a short-shift gear change fitted. Is this because the throw back-and-forth of the standard gear stick is too long and would hit the metal of the gate? Does the actual gear stick rod not fit between the slats of the H-Gate? Is the only way to achieve this look by having the short shift and then the gear stick just moves around the area in the middle but never actually go in between the slats? My centre-console where the gear stick is, would be lower than the standard mr2 one so would i get away with it? thanks in advance for your help guys

Paulie
Title: Re: Paul's 4thirty Build
Post by: Lee22 on February 15, 2015, 06:38:39 PM
I'm glad your doing this first Paul, as your asking all the questions I currenlty have... ;D

Lee
Title: Re: Paul's 4thirty Build
Post by: MADMAN on February 15, 2015, 10:04:17 PM
Yes Paul, I fit a short shifter from ebay aprox £40 and I also fitted a thinner gear lever to look as though it will fit through the H gate even though it only pivots in the centre and not into the gate. I lowered my console so the H gate was as low as possible at the base of gear lever. I dodnt know if this is the only way to achieve this, but it seemed the easiest way round the problem to me.
any more info give me a shout
MADMAN  8)
Title: Re: Paul's 4thirty Build
Post by: Lee22 on February 15, 2015, 10:49:49 PM
Thanks madman,

That's answered some of my questions too... ;D
Title: Re: Paul's 4thirty Build
Post by: cheets on February 16, 2015, 03:40:04 AM
that is ok Paul think i need to do the sanme as you and make the slope on the font a bit more
Title: Re: Paul's 4thirty Build
Post by: Darren on February 16, 2015, 08:38:31 AM
Hi Paul, I fitted a Mk2 short shift, this has brought the pivet point down as low as possible to enable the gate shift to work, there was a fair bit of welding and fabrication involved, not sure how much the Mk3 short shifters lower the knuckle joint. I realise my set up with cables etc.. is totally different, but it's just trying to get that oem look. What ever you do it will be an improvement on the high position of Mk3 gear shift

Here's mine from a few years ago
(http://i8.photobucket.com/albums/a13/dangerrous/finishedgearshifter.jpg) (http://s8.photobucket.com/user/dangerrous/media/finishedgearshifter.jpg.html)

As you can see the gear lever is basically a stub! I will be extending it once I've sorted out the centre consul
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 17, 2015, 07:09:58 PM
Thanks for all the help and comments guys. I spoke with Paul woods and he said my gearbox setup will be completely different to standard mr2 so I'll just wait. If needs be I can get something made up when I get round to it.  I'm probably gonna redo the whole centre console in wood now so what I did was just a practice.

As for the v6. Engine bay was all prepared and painted last week. The plan was to get the engine hanging  on Monday.  :D.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on March 01, 2015, 01:58:01 PM
V6 Update

The car has been away for 8 weeks now and things progressing well and all that is left to do is the exhaust system and wiring. I don' have any pictures as I have just been letting Paul get on with the job and tried not to bother him too much. But should be done within 2 weeks.

While the car is up there I am also having new uprated discs and pads put on all round - might as well while all the spacers are off etc..

so when the car comes back, the 1st project will be to fit the dummy engine back. Shouldn't take too long as I have all the pieces ready.

Then it will be working on the centre console. I am going to re-do it from scratch and make it all out of wood and then get it covered in the same Ferrari biege leather as the seats and door cards. I have an H-Gate to try (thanks a million Wizard) but chances are I will have to get something made I think. It would be the icing on the cake if I can make it work and have the gear stick go in and out of the slots.

And last thing to report, I have bitten the bullet and ordered the 430 dash kit.  ;D I will pick it up on the way to get the car.  I ummed and ahhhed about whether to do this, and was possibly going to go down the turisimo dash option, but they come out at the same price really. I did also think about doing something like V8 KLR has done with the vents, but time is something I don't really have at the moment, so didn't want to waste time working on something if it wasn't going to turn out any good. We all know how good the dash kits are and how they really finish off the interior.

Title: Re: Paul's 4thirty Build
Post by: Paul79 on March 13, 2015, 07:40:16 PM
Woodsport told me yesterday that the exhaust system is nearly done. So hopefully we are on the last lap now. Fingers crossed.
Title: Re: Paul's 4thirty Build
Post by: beemaman on March 13, 2015, 07:49:27 PM
Fingers crossed Paul :) stoneliegh in the big v6 :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on March 14, 2015, 10:10:35 PM
With the car being away for so long now and the weather starting to improve (a little) I’ve been thinking up things to pass the time! I know I’ll have a few projects to do when its back (centre console and dash) but it suddenly struck me that I could have a go at doing a replica car key.

I know a few guys have done this and made some really, really good ones (Beany, Madman and Beemaman) but they have all involved modifying the Toyota key and incorporating the buttons into the main unit. They look fantastic but I am not sure I could get it as good as they have done. So I thought about another route. The thing is, most people don’t know what the inside of a Ferrari looks like, let alone a Ferrari key, so you can get away with anything that looks ‘Ferrari like’   If it is coloured and has a badge on it, it would surely pass as a Ferrari key.

So I typed into eBay, ‘Ferrari key’ and found this:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4276_zpsfde1748b.png) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4276_zpsfde1748b.png.html)

I thought that looks good and cheap – I wonder if it comes apart so I can put in a MR2 blade instead? So I emailed the seller asking him the question. It didn't  :( And then he asked why I would want to take it apart so I told him what I was planning to do. He then pointed me in the direction of this key. It is from an Alfa and comes apart and I could just change the blade and put a Ferrari badge on instead of the Alfa one. And just look at the price!  So I had to buy it and see. 

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6640_zps7735c3bf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6640_zps7735c3bf.jpg.html)

It turned up the next day and I must say, it looked really good. Solid plastic and nice and Rosso. Clicks apart and the blade is held in place with a screw. The Alfa badge came off easily. It is a little smaller than the MR2 key, but that isn’t a bad thing really I suppose. Just different.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6648_zpscb58a8d6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6648_zpscb58a8d6.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6649_zpsab55a9a6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6649_zpsab55a9a6.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6650_zpse98acc99.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6650_zpse98acc99.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on March 14, 2015, 10:24:55 PM
The MR2 key here is a blank one I had bought previously off eBay with a transponder for around £25 which I had already cut. So I bought a couple more blank keys off eBay (without transponders) for around £4 each and had them cut the same. 

***I strongly advise you do the same and not try this out straight on your main car key just in case things go wrong. You don’t want to ruin your only key for the car***  these blank keys are very cheap and getting it cut will only cost £5 so better to be safe than sorry!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6667_zpscf77c53b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6667_zpscf77c53b.jpg.html)

I undid the screw on the back to exposure the inside. Before I did this I scored a line in the blade just below where it meets the black plastic so I knew a) which was the back part of the blade and b) where the blade was exposed from when it was a MR2 blade so I could ensure the same amount stuck out when it was in the Alfa key.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6668_zps489b756f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6668_zps489b756f.jpg.html)

To remove the blade there is plastic on the inside that you need to grind away carefully.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6669_zps2977cc74.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6669_zps2977cc74.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6671_zpse1a3d9a6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6671_zpse1a3d9a6.jpg.html)

And then it will come free

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6672_zps4c19da0d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6672_zps4c19da0d.jpg.html)

You then need to grind away part of the lugs at the top to enable the blade to slide inside the gap in the Alfa key. But take your time on this as the slit in the Alfa key is bigger than the width of the MR2 blade. So you don’t need to grind the lugs all the way to the blade edge otherwise the blade will move sideways a bit once you have screwed it in place.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6677_zpsea01b320.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6677_zpsea01b320.jpg.html)

Finally put the MR2 blade in the Alfa key and screwed into place

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6679_zpsd3cf4acc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6679_zpsd3cf4acc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6680_zps6405419e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6680_zps6405419e.jpg.html)

The left over MR2 fob part I plan to still use as the key fob to open the doors and have  set up like below. I am just waiting for the Ferrari badge to turn up to stick on the Alfa key

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6682_zpsa7c4c02c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6682_zpsa7c4c02c.jpg.html)

Title: Re: Paul's 4thirty Build
Post by: Wizard on March 14, 2015, 10:33:30 PM
Paul, as always a fantastic write up and a very cost effective way of gettin that Ferrari key "look"
Title: Re: Paul's 4thirty Build
Post by: cheets on March 15, 2015, 01:59:42 AM
Looking as good as ever :)
Title: Re: Paul's 4thirty Build
Post by: ghall164 on March 15, 2015, 02:00:52 PM
Nice work and great write up as usual paul ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on March 22, 2015, 04:46:58 PM
A further update on my replica key project

I have purchased some of these universal key fobs off eBay with a view to hoping to use these when my replica key is done. I bought some of these to replace my house alarm key fob and they look ace. And were very easy to program.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4301_zpsf8ce5299.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4301_zpsf8ce5299.jpg.html)

Also for the ring that goes through the hole in the key I bought some hinged split rings so I can put the ring on without scratching the key.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4303_zps6380688b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4303_zps6380688b.jpg.html)

I glued a washer in the alfa key to filled some of the gap whilst I waited for my shield to turn up

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4304_zps28aba48b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4304_zps28aba48b.jpg.html)

Now apologies to Wizard and Beems as I’ve been chewing their ears off all week with my badge dilemmas! The thing is, I have bought numerous different badges and none have seemed to work. I bought one nice enamel one (a tie pin) off ebay that said it was 20mm high. This would have been perfect. Turns out it was only 15mm high and thus too small to cover the hole in the alfa key. Doh! And then the fiasco began. I bought various resin badges for various places and all were either too small or too large! Beems even kindly sent me one he had, but again it was too big! LOL.

I had planned to make a few keys for myself, so I had bought another alfa key and a couple of blank MR2 keys aswell but seems that the alfa key is just too slim. Here it is with the best fitting sticker badge on it. Doesn’t look too bad I suppose.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4309_zps326b4ce8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4309_zps326b4ce8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4311_zps7b90bc34.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4311_zps7b90bc34.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Lee22 on March 22, 2015, 05:53:55 PM
Paul,

What size round one do you need?

The picture I have attached has 3 round ones on it.

The latest one is 14mm in diameter



And this is whee I got them from :

http://www.ebay.co.uk/itm/FERRARI-domed-badge-vinyl-sticker-set-for-remote-key-fob-/331509933157?pt=LH_DefaultDomain_3&hash=item4d2f882465

Title: Re: Paul's 4thirty Build
Post by: Paul79 on March 22, 2015, 06:03:06 PM
So there reason I went down my Alfa key route was because I didn’t think I could make a proper key like the big boys. However seeing as I wasn’t that happy with the Alfa key and the badge issues I changed my mind and gave it a shot. I’d had quite a few beers Friday night so stumbled into the garage and started to have a go.

As Beany did, I found a key on the web and traced onto paper and used this as a template.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4325_zps0ffdf234.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4325_zps0ffdf234.jpg.html)

I used one of my blank keys and taped up the blade and then cut away the top part

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4326_zps6ba4cdf2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4326_zps6ba4cdf2.jpg.html)

I roughed up both sides good and properly so the fibre glass had something to really grip into and then started mixing. I stuck a load of the FG onto the paper template and then pressed the blank key into it

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4327_zps670ef549.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4327_zps670ef549.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4328_zpsd8d2ad0e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4328_zpsd8d2ad0e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4329_zps25c5b409.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4329_zps25c5b409.jpg.html)

Once it had gone off overnight, I cut away the paper and ground the remaining paper away. I repeated the whole process on the other side to gradually build up the shape required. It is worth nothing, I am not going down the route with the transponder inside, so this is somewhat easier.

You end up with something like this

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4330_zps1d2e7d78.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4330_zps1d2e7d78.jpg.html)

Then you start the pain-staking process of filling, sanding, filling, sanding etc.. I also sprayed with primer to truly see if it was getting there as when it is all one colour it is easier to see the imperfections.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4331_zps18ae64e7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4331_zps18ae64e7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4332_zps7beca88b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4332_zps7beca88b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4341_zpsc0f3b51b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4341_zpsc0f3b51b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4342_zps860b856d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4342_zps860b856d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4343_zps50a71132.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4343_zps50a71132.jpg.html)

You eventually end up with something that resembles a mini-magnum (as my wife says).  This has got filler primer on it here which is why it is yellow.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4347_zps10b49f6a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4347_zps10b49f6a.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on March 22, 2015, 06:21:54 PM
Yesterday yet more badges turned up (I’ve forgotten what I’ve ordered I’ve bought so many) Haha

This time there were 2 sizes, so I did a test to see how they would looked. What do people think. Big or small?

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4352_zps8ede1e91.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4352_zps8ede1e91.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4353_zpse49dbd48.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4353_zpse49dbd48.jpg.html)

Then was the nervous bit of drilling the hole. Luckily it turned out ok

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4363_zpsc4fb19c0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4363_zpsc4fb19c0.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4364_zps4215e567.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4364_zps4215e567.jpg.html)

Back to the filling and sanding then!!!
Title: Re: Paul's 4thirty Build
Post by: Sir Percival on March 22, 2015, 09:21:04 PM
Small....I think....don't know if its my computer but your key looks gigantic. :o

Look on the bright side....at least you can wallpaper the spare bedroom with all the stickers and badges you have ordered and will have knocking about ;D

Sir P
Title: Re: Paul's 4thirty Build
Post by: Furrari on March 23, 2015, 08:42:14 AM
Unfortunately you can't make a Merc key look anything like this.  I might (eventually) just have one on my key ring to look cool.  :-)
Title: Re: Paul's 4thirty Build
Post by: ferrari feb 14 on March 23, 2015, 12:55:47 PM
Defoe the small badge Paul ,looking gud tho ,jd
Title: Re: Paul's 4thirty Build
Post by: Lee22 on March 23, 2015, 01:11:51 PM
No contest Paul

The small one wins everytime! (Well that's what I have to tell Claire anyway ::))
Title: Re: Paul's 4thirty Build
Post by: beemaman on March 23, 2015, 01:24:37 PM
lee its not all about the size :) sometimes small is better :) well thats what madman keeps telling me :) :) :)

nice badge paul alooking good will it be as fast as the v6 in your car now ??
Title: Re: Paul's 4thirty Build
Post by: Paul79 on March 23, 2015, 07:41:09 PM
Lol. Cheers guys. But what colour do I paint the key?  v6 Beems? Don't. It's getting unbearable now. Hoping just before Easter it back for some chocolate.
Title: Re: Paul's 4thirty Build
Post by: Wizard on March 23, 2015, 08:43:22 PM
I really hate to say it, but the key needs to be RED.
Title: Re: Paul's 4thirty Build
Post by: MADMAN on March 23, 2015, 10:11:54 PM
lee its not all about the size :) sometimes small is better :) well thats what madman keeps telling me :) :) :)

nice badge paul alooking good will it be as fast as the v6 in your car now ??

            Yes I do keep telling you small is better, but that is only so you wont be upset and jealous of BIGGER ones ;) ;)
MADMAN ;D
Title: Re: Paul's 4thirty Build
Post by: beemaman on March 23, 2015, 10:19:37 PM
Lol Steve I know mate ive got a complex you see that's shy I have a ferrari replica to try make up for the size :) :)

Oh yeah Paul it has to be red.send it over if you want a coat of primer on and a few coats of glossy Rosso red :)
Title: Re: Paul's 4thirty Build
Post by: Lee22 on March 23, 2015, 10:44:32 PM
Can I do the same with my whole car Wayne.... Lol. ;D

I'll just drop it over for a quick coat of white (in certain areas), it won't take you long ..? ;)

Lee

Ps - Paul, paint the key a proper colour mate...... WHITE  ;D
Title: Re: Paul's 4thirty Build
Post by: beemaman on March 24, 2015, 01:26:42 PM
hi lee

yeah no probs mate bring it over ile do it for you but be aware that it wont be any better than it is now cus its mint and looks like it was only painted last week :)
Title: Re: Paul's 4thirty Build
Post by: Lee22 on March 24, 2015, 02:06:46 PM
Very true Wayne....
99% of the car is PERFECT...... Just a couple of 'underneath' bit to do, I'm afraid...

Sleeping police men, I think have been the problem  ???....
Title: Re: Paul's 4thirty Build
Post by: Lee22 on March 24, 2015, 02:08:47 PM
SORRY Paul,

Didn't mean to :

Title: Re: Paul's 4thirty Build
Post by: Paul79 on March 25, 2015, 06:59:11 PM
V6 update. Engine wiring is all done. All that is left is to make the air intake pipe and then new brakes and testing. On the home straight. ☺️☺️☺️
Title: Re: Paul's 4thirty Build
Post by: Lee22 on March 25, 2015, 10:01:21 PM
Fantastic news Paul....

I bet you can't wait now...!

Are you popping in on the way back home... I'do love to see it ::)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on March 26, 2015, 06:52:39 PM
More key pictures
Title: Re: Paul's 4thirty Build
Post by: Paul79 on March 26, 2015, 07:00:31 PM
So the key is finally done. Added a photo to show the difference between the replica key and the mr2 original. Big thanks to Wayne for his tips on painting and lacquering. What's next on the list? 😉
Title: Re: Paul's 4thirty Build
Post by: Roccoracing on March 26, 2015, 07:47:34 PM
Top Job that Paul,   If only the ford keys where that small !

Title: Re: Paul's 4thirty Build
Post by: CharlieMoss on March 27, 2015, 12:22:49 AM
Looks naughty mate :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on March 28, 2015, 03:21:37 PM
Further key update:

Now, I had envisaged this problem before I even started making the key, but didn’t expect it to happen so soon. The issue is with the hole at the top of the key and the metal ring that goes through it. The metal ring seemed to take to rubbing the paint off the key and damaging the hole I had drilled. Below you can see it started to happen.  :( :( Has anyone else had this issue?

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4414_zpsmicvunje.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4414_zpsmicvunje.jpg.html)


What I needed was some sort of washer with a lip and a hole but that still had a tube in the middle to line the hole with each side. Then the metal ring would rest against metal and thus not scratch the paint. I know it isn’t Ferrari like but it woiuld make the key much more practical.

So I racked my brains and thought that these would work. Below is 4 pieces that come when you buy a set of metal poppers that go on your clothes.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4415_zpsllwrund8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4415_zpsllwrund8.jpg.html)


I could use this piece and if I drilled out the dimple part so there was a hole I could use one each side and effectively line the hole with metal. I chose gun-metal grey poppers so it would stand out less against the red key. They come in a set of 10 for £1.50 so I had a few pieces to practice on

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4416_zpsea35mf7i.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4416_zpsea35mf7i.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4417_zpsipjipv5u.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4417_zpsipjipv5u.jpg.html)


I carefully drilled out the dimple and then filled it down a bit further.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4418_zpsjirhurx5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4418_zpsjirhurx5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4419_zpsbv8alv0j.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4419_zpsbv8alv0j.jpg.html)


I repeated on another piece and then tested that the silver ring would fit through ok and then glue one to each side of the key.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4422_zpsyrch3xii.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4422_zpsyrch3xii.jpg.html)


I know it looks a bit different, but it certainly much more practical and it looks better in the flesh. So now the keys look like this and I they can hang like this without the danger of the hole getting scratched and worn.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4423_zpsweuusyyi.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4423_zpsweuusyyi.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4424_zpso47yehhj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4424_zpso47yehhj.jpg.html)


Simples!   ;D ;D ;D
Title: Re: Paul's 4thirty Build
Post by: cheets on March 28, 2015, 10:31:07 PM
I am liking it think i will have to have a go at making one :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on April 01, 2015, 08:21:12 PM
V6 update

I finally have a date. April 14th is pickup day.  Hooray! It's been a long time but will be worth it.  ;D
Title: Re: Paul's 4thirty Build
Post by: Phils99 on April 01, 2015, 08:26:43 PM
WOW! brilliant news mate!!
Title: Re: Paul's 4thirty Build
Post by: Wizard on April 01, 2015, 08:59:43 PM
Paul,  bet u can wait to get her back now, it's been a while. We "will" need lots of video updates.
Title: Re: Paul's 4thirty Build
Post by: V8 KLR on April 02, 2015, 12:51:52 PM
That's great news next thing is to find the nearest garage that sells 98RON UNLEADED go for a blast get the exhaust nice and hot and wait for the pops and bangs...... ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on April 02, 2015, 07:02:50 PM
Yep. I'll do plenty of walk around videos of the engine bay.

Looking forward to the noise and back popping. So is that the best fuel to use. The more expensive unleaded?
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on April 02, 2015, 10:51:52 PM
Paul,
All I can say is prepare yourself for an overdose of smiles as big as you can get.
You will be wowed all the way home.
Enjoy.
Rudy
Title: Re: Paul's 4thirty Build
Post by: Paul79 on April 02, 2015, 11:31:39 PM
Cheers. I've just counted. It's 12 days till Christmas. And on that note, Happy Easter everyone.  ;D
Title: Re: Paul's 4thirty Build
Post by: V8 KLR on April 03, 2015, 02:18:37 PM
Yes the more expensive type gives a bit more power not that you need it ha ha..... ;D and cos its a higher octane it does pop and bang better... :o
Title: Re: Paul's 4thirty Build
Post by: Lord Beany on April 09, 2015, 09:36:58 PM
That's all I out in mine and it makes some cracking noises. I'm sure it probably spits the occasional flame out the back too. ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on April 09, 2015, 10:08:00 PM
LOL -  5 more sleeps!  ;D ;D ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on April 12, 2015, 09:10:07 AM
I took the girls to Legoland over Easter, and I had a feeling the gift shop would have something for me! So I treated myself to this.... ;D

Title: Re: Paul's 4thirty Build
Post by: Paul79 on April 12, 2015, 09:13:21 AM
....so in true Paul's build diary style: here is the build thread!
Title: Re: Paul's 4thirty Build
Post by: Paul79 on April 12, 2015, 09:13:55 AM
.
Title: Re: Paul's 4thirty Build
Post by: johnjames on April 12, 2015, 09:31:55 AM
Hi Paul,
           so the secret is out DNA new prototype is that you Paul standing beside it with a big spanner take care mate looking forward to seeing you at Stoneleigh.  J J
Title: Re: Paul's 4thirty Build
Post by: Furrari on April 12, 2015, 11:17:16 AM
And the colour' still wrong.  ;)
Title: Re: Paul's 4thirty Build
Post by: Lee22 on April 12, 2015, 12:54:29 PM
Great thread Paul...

Made me laugh... ;D

Love the new car build..
Title: Re: Paul's 4thirty Build
Post by: Sir Percival on April 12, 2015, 08:05:01 PM
Nice one Paul...............hope its got the V6 in it ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on April 13, 2015, 09:48:32 PM
Off to sleep in a minute as I've got an early start - 1 more sleep to go!!!

I got sent these today  - a taster of things to come! When I asked what it sounded like - Paul Woods replied: "Like a Ferrari!" 

That's good enough for me!  ;D ;D ;D
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on April 13, 2015, 10:59:35 PM
Paul, hope you can sleep.
I was restless the night before and just counting the hours.
Enjoy my friend. Welcome to the V6 club.
Look forward to your posts tomorrow. :)
Title: Re: Paul's 4thirty Build
Post by: Phils99 on April 14, 2015, 08:04:40 AM
have a fun day mate....unlike me, I think you have got the nice weather to pick her up!
Title: Re: Paul's 4thirty Build
Post by: Paul79 on April 14, 2015, 10:30:20 PM
Hello peeps. Pleased to report car is now home safe and sound. What a day! Car is immense! Off to bed as driven over 700 miles today and absolutely knackered. Full report tomorrow.  ;D
Title: Re: Paul's 4thirty Build
Post by: Wizard on April 14, 2015, 11:52:36 PM
Paul,  glad it all went well. Look foward to the updates tomorrow.

Ps I know I wasn't the only one checking the forum every few hours for an update on your thread. Everyone on this forum is excited to hear all about your new car.
Title: Re: Paul's 4thirty Build
Post by: Furrari on April 14, 2015, 11:54:03 PM
I bet it's the most fun you have ever driven.  Having a bit of power makes driving a lot easier.
Title: Re: Paul's 4thirty Build
Post by: MADMAN on April 15, 2015, 08:49:19 AM
Glad you got home safe and sound, Have a good sleep with pleasant dreams of your Fantastic car
MADMAN 8)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on April 15, 2015, 10:19:35 PM
So now I have had a full day to come back down to earth, here it the full report of the day:

Dad and I left home 5.30am for the 5 hour drive from up north to Durham. Hit DNA HQ about 8am to pick up my dashboard kit (next project). Nice to see the guys again. Then it was onto Woodsport. We got there around 12.30pm and the car was sitting there all clean up with rear deck open.  The engine installed looked immaculate and fills the engine bay just lovely.  Paul went through loads of things in fine detail and answered all questions I had. Then it was time to fire her up. OMG – what a noise! It sounds immense, like a jet plane taking off. Then it gradually settled downs to a nice rumble. Paul has a very flash ODBI reader installed and was going through everything showing me how things work. Then as if on cue, when the engine temperature reaches 80 degrees, the revs drop again. Then it was time to give it some throttle! Big smiles all round.

So it was time to leave. As he lives only a few miles away we call in on JD and had a look at his Extreme 360. Thanks again for hosting us John and nice to see you. Then we left and headed south. Weather was lovely so it was roof off all the way home. Paul Woods had told me to take it easy on the way home as he hadn’t had time to do as much road testing as he would have liked, but a 300 mile ride home would be a good test. Car drives like a completely different car. Feels really solid and planted. Exhaust screams if you want it to and you get the lovely burble and back popping noise as well. I made sure I filled up with super unleaded as well. At 70/80mph in 5th you can cruise and the car it almost silent  which is good for the ears on long  motorway journey’s.  But you only need to tap the gas pedal and the noise comes back reminding you what it can sound like. Lots of waves and stares on the way home, and was overtaken by a real black 458. The driver didn’t look very happy tbh, as he gave me a sideways glance.

Stopped off at Dr MADMANs for a mid-journey inspection in the surgery (Aladdin caves) thanks again for everything Steve. If you look closely in the pictures you can see the Dr underneath the car. And then we had to head home. Didn’t get back till 9pm and last hour was night driving, but car never missed a beat. Great day.  Definitely money well spent in my opinion

After work today I started the car up in the garage so my wife and girls could hear. They jumped out of their skin! LOL. 
Thanks to everyone involved but especially my Dad who without, none of this would have been possible. Love you Dad! x
Title: Re: Paul's 4thirty Build
Post by: Paul79 on April 15, 2015, 10:28:20 PM
almost forget: here is the eagerly awaited video! speakers on!!!  ;D ;D ;D

https://youtu.be/sxTFMXtwc0k

Title: Re: Paul's 4thirty Build
Post by: rudycob1 on April 15, 2015, 10:57:27 PM
Looks and sounds great mate.
Hope you are pleased with it.
It's amazing .
Title: Re: Paul's 4thirty Build
Post by: Wizard on April 15, 2015, 11:04:32 PM
Wow wow wow. That sound insane. Really pleased it's exactly what you wanted. Still can't believe how loud it sound.  ;D
Title: Re: Paul's 4thirty Build
Post by: kalifornia on April 16, 2015, 07:17:18 AM
Reminds me when Paul did one for me on my old 355 conversion. Enjoy
Title: Re: Paul's 4thirty Build
Post by: Phils99 on April 16, 2015, 12:23:50 PM
Damn!!! you got me wanting one now!!!!...it will have to wait until next year to save up the pennies.....
Title: Re: Paul's 4thirty Build
Post by: V8 KLR on April 16, 2015, 05:43:11 PM
Sounds good mate cant wait till we are out on a convoy..... ;D
Title: Re: Paul's 4thirty Build
Post by: Sir Percival on April 16, 2015, 07:44:20 PM
Looks and sounds fabulous Paul
Title: Re: Paul's 4thirty Build
Post by: MADMAN on April 16, 2015, 11:00:06 PM
Looks and sounds better in the flesh, nice one Paul
MADMAN 8)
Title: Re: Paul's 4thirty Build
Post by: Furrari on April 17, 2015, 08:04:50 AM
I'd count them cylinders, there sounds more than six of them to me.  What a sound.
Title: Re: Paul's 4thirty Build
Post by: ferrari feb 14 on April 17, 2015, 08:41:50 AM
Hey Paul was great to see you and your car again the engine sounds awesome well worth the wait ,pleased you had a safe trip home ,see you at stoneleigh ,jd.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on April 18, 2015, 09:43:25 PM
Ok so this morning was the first time since getting the car back I could do some proper work. I'd been fiddling in the evenings with the engine cover deciding how to do it. I'd planned to replace the chequered plate I had with a grill and then have an aluminium bar to support the hinges for the engine cover. During the week I'd been tweaking it to see how the cover would fit. I finally got it all sorted. Screwed the grill in place and then added the bar and hinges. Used my ordinal strings and all is well. I decided to loose the power steering pump as it was hitting the plenum. I might add it back later but it allows to see more of the V6 set up. I know it isn't like the real ferrari set up but I think it looks good enough! 😄
Title: Re: Paul's 4thirty Build
Post by: Wizard on April 18, 2015, 09:53:46 PM
Paul, your build just gets better and better. Dummy engine looks brilliant with v6 underneath.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on April 18, 2015, 09:59:17 PM
Also tried out my dash aswell. Below is before and after. Next project. 😉
Title: Re: Paul's 4thirty Build
Post by: beemaman on April 18, 2015, 10:03:07 PM
Looks great mate you wait til its trimmed and fitted will look great :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on April 18, 2015, 10:22:23 PM
So gave the car a quick clean. Woodsport had cleaned and polished it lovely but there was still a lot of dust in the hard to reach places. Got that all sorted and the V8 KLR came over and then we went for a blast. It was the first time I'd taken Dad out in the car.  I think he like it but he'll stick to Jags me thinks.

Then it was time to take the family out for a spin. Took Jules for a spin and then let her drive. My word. She's braver than me. She was really giving it some. I was proper scared. Then took the in laws out and suddenly a real F40 was following me and then a R8 Spider. Lots of noise. 😃

Here's some pictures
Title: Re: Paul's 4thirty Build
Post by: Paul79 on April 29, 2015, 09:29:05 PM
Just bought these. Hope to fit them up the weekend after Stoneleigh  ;D ;D ;D
Title: Re: Paul's 4thirty Build
Post by: Ronan7051 on April 30, 2015, 11:41:53 PM
Hi Paul,

I've just caught up on your thread and as usual, all I can say is wow! Car looking stunning and so is the engine conversion, brilliant job, bet your delighted with it, enjoy bud! Won't be at stoneleigh as stuck at work, but might try and arrange to meet sometime when I'm flying through Heathrow, or at some of the other shows over the summer, if I'm home for them.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 02, 2015, 06:53:25 AM
thanks for all the comments guys  ;D - here a couple of other photos. last weekend took the car away for a trip to bath. weather was a bit iffy so i had invested in this roof cover. just a cheap one off ebay, but it was just a top cover for a hatchback, that i then turned around the other way and secured. the rain wasn't going to be heavy but it did the job just in case...i also stumbled across this aftershave in Boots - was on offer £10.99 reduced down from £30! it didn't smell too bad either so i shipped 2 bottles in! the badge on the bottle is also a raised resin one which could be perfect for a replica key  ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 02, 2015, 07:00:13 AM
Also Santa visited my house yesterday. Only ordered them Wednesday night and they were here Friday! They look lovely and weight a ton.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 02, 2015, 07:09:35 AM
also when Andy came over the other day we compared the engine installs. there is probably about 1 year between them and it was interesting to see the slight differences between them  - the location of various components etc..
Title: Re: Paul's 4thirty Build
Post by: paulcas on May 02, 2015, 10:18:02 AM
thanks for all the comments guys  ;D - here a couple of other photos. last weekend took the car away for a trip to bath. weather was a bit iffy so i had invested in this roof cover. just a cheap one off ebay, but it was just a top cover for a hatchback, that i then turned around the other way and secured. the rain wasn't going to be heavy but it did the job just in case...i also stumbled across this aftershave in Boots - was on offer £10.99 reduced down from £30! it didn't smell too bad either so i shipped 2 bottles in! the badge on the bottle is also a raised resin one which could be perfect for a replica key  ;D
Hi Paulie,  I got some of that aftershave for Christmas. It's quite nice, mind you I thought Brute aftershave was nice as well!



Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 16, 2015, 10:15:05 PM
Well. The suspension is all done. As for me, I'm done in! 😴😴😴.  Full update tomorrow.
Title: Re: Paul's 4thirty Build
Post by: Lee22 on May 16, 2015, 10:38:04 PM
Looking forward to the pictures Paul.

I hope it looks something like this mate...!! ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 17, 2015, 10:14:24 AM
Coil-over Suspension Change


Firstly, I would like to say a HUGE thank you to Andy (V8 KLR) for giving up his whole Saturday to help me do this. It is a big, tiring job, and definitely should be done with 2 people if you want to get it done in a day.  Andy was great especially his knowledge of the whole set up as he has it on his car as well. Thanks also to Dad for his help along with some filming.  Finally, apologies for the lack of pictures - it was just one of those things where I forgot to take pictures along the way as I was so focused on getting the job done.

I started early before Andy arrive and got the car out, jacked it up and took all 4 wheels off and let it sit on Axle stands. I also took the opportunity to remove the front, lower arch liners and under bumper cover to allow me to work on my tow-eye bracket later on.  I removed the fake callipers and discs, as these would just get in the way and took the opportunity to give them all a good clean. Then I gave the arches and liners a quick clean as well as they were covered in mud. Also while the wheels were off I also cleaned the insides of them as well. You need to remove the under bonnet, frunk-surround cover to exposure the suspension turrets and bolts there too.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4769_zpslkia5oee.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4769_zpslkia5oee.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4770_zpswrjelsok.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4770_zpswrjelsok.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4777_zpsku70j8mt.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4777_zpsku70j8mt.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4778_zpspj0lgksp.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4778_zpspj0lgksp.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4779_zpssbgbgawm.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4779_zpssbgbgawm.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4783_zpsnubeypkw.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4783_zpsnubeypkw.jpg.html)


Old parts

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4786_zpszmhcgmmx.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4786_zpszmhcgmmx.jpg.html)



Rear Suspension


The rears are fairly straight forward. Remove the MR2 set up, undo the 2 bolts holding the hub to the suspension leg, undo the brake pipe from the bracket, undo the drop links (these are a nightmare – we discovered that the thread that the nut goes on, is hollow and has the shape of an allen key hole inside it. These will probably be full of muck, but you need to put the allen key inside and then undo the nut otherwise the thread will just spin), undo the 3 nuts at the top of the suspension turret and drop out the whole leg. You don’t need spring compressors. Support the hub with a jack to avoid undue stress on the brake pipes while it is all apart.  The jack helps manoeuvre the hub back into the new coil over leg as well. Put the new coil over in place, do the bolts up at the top of the leg inside the engine bay, put the hub back in place and do all nuts up.

The height of the coil overs is adjusted by rotating the leg at the bottom to exposure more or less threads. This is a trial and error process. We set it at 8.5cm from the top of the lock nut at the bottom to the bottom of the big purple nut just beneath the springs. We fitted both sides up and the whole thing was too high. In the end we got set it to a 4.5cm gap, but again it is all personal preference.  This gives a ride height gap at the top of 3 fingers.

The kit comes with some brackets for the rear to support the brake pipes but these don’t fit, so we adapted them and fitted the pipes up in their most natural position. Sorry I didn’t get photos of this in the end.  I will do next time I have the rear wheels off. We did all nuts up tight (without thread lock for the road test) and once we were happy with it all, re-did them with thread lock.


Front Suspension


Again you don’t need springs compressors – take all the MR2 parts off and replace with the coil overs. I was prepared for needing longer bolts for the DNA bracket but I didn’t need them in the end. I found that the DNA bracket that is supplied in the kit didn’t sit flush with the new suspension leg. (This is the bracket that is designed to change the camber of the MR2 when you build the 430 kit originally – the one that is basically 2 plates with 4 bolts and 2 spacers the same width as the hub connections) The welds on the new leg protruded and butted up against the DNA bracket.

So I had 2 options. 1) Space out the bracket so it missed the welds (which meant I’d probably need the longer bolts), or 2) trim the bracket slightly. I chose the trim the pointy bits off the bracket ever so slightly. (See photo below). Once trimmed I painted them up and then put it all back together all sitting flush.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4788_zpsg2dejhhr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4788_zpsg2dejhhr.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4787_zpsmb9wbcle.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4787_zpsmb9wbcle.jpg.html)

You do however, need washers for the outer 2 bolts – the ones that actually hold the hub in place to the suspension leg. 2 on each bolt between the DNA bracket piece and the hub itself. (See photos)

What you also need to do is make some brackets to hold the brake pipes and brake-pad sensors. Andy had the great idea of using a jubilee clip and then L-shaped brackets slipped inside the clip and then more L-brackets and nuts and bolts to support the pipes/wires. See photos for what we did. Again you want the pipes/wires to sit in their most natural positions.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4789_zpsyyzgqusk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4789_zpsyyzgqusk.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4791_zps7xs6w2ql.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4791_zps7xs6w2ql.jpg.html)


When installing the new leg, the 3 nuts at the top are very fiddly. 1 in particular due to the fact it is right under the wind and very hard to get to. Plus the new leg threads are longer than the original MR2 ones. The best way to install it is get the easiest thread thru and the nut on a couple of turns to support the weight, then you want to tilt the leg so the most awkward thread is just poking thru and get another person to ease the nut on a couple of turns. You’ll know what I mean when you do it. It would be very difficult to do on your own.

For the front legs we set them at 7.5cm gap and this turned out to be the perfect ride height. We also set the camber dead-straight for now and now the car is back on the ground you can really notice it being straight. The original DNA/MR2 set up has more camber naturally so the wheels slope inwards/upwards.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4789_zpseddpkzz7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4789_zpseddpkzz7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4789_zpsxgrxgtsc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4789_zpsxgrxgtsc.jpg.html)


Once we were all done we road-tested the car. Drives very well and Andy was impressed, especially with the front. The nasty bumps and bangs have gone and the car is much more driveable. We didn’t really thrash it as nothing was thread locked at this point. I am also happy with the ride height. The rear is a little higher than before but that is needed to avoid the drive shafts hitting the sub frame. Once road-tested we thread locked everything up and put it all back together. I will probably get it all aligned properly at a specialist to set it all up correctly for the car, so I will leave the under bonnet cover off for now.

Big thanks again to Andy for all his help.  ;D ;D ;D
 
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 17, 2015, 10:29:27 AM
Here's the video shot today.  ;D

https://youtu.be/tAzNk0qP2I8
Title: Re: Paul's 4thirty Build
Post by: Georgelooney on May 17, 2015, 12:36:20 PM
She looks and sounds amazing Paul  :)
Title: Re: Paul's 4thirty Build
Post by: Spacecowboy on May 17, 2015, 04:04:21 PM
Looking very nice. How does she feel now?
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 19, 2015, 09:31:39 PM
Haven't e really had chance to test yet.  :( Hopefully this weekend. But from what I have done, she feels a lot more solid and planted.  ;D. Will let you know
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 19, 2015, 09:36:01 PM
....as you saw in the last video, the car was on pieces of wood, to create a bit more ground clearance to get the big trolley jack underneath. So afterwards I had the idea to make these out of off cuts of wood - total cost £0 - for next time...
Title: Re: Paul's 4thirty Build
Post by: Daz on May 19, 2015, 10:36:34 PM
Are You ETCHING The CHASSIS Using A GRINDER OR JUST SAND PAPER? Do you THEN Use A SPRAY PRIMER And THEN THE PRIMER SUPPLIED WITH THE KIT? OR JUST USING THE KIT PRIMER? ALO DOES IT Have To GO BACK TO METAL ? SORRY ABOUT TEXT KEYS PLAYING Up ON LAPTOP LOL
Title: Re: Paul's 4thirty Build
Post by: DNA AUTOMOTIVE on May 19, 2015, 10:39:39 PM
just take the glaze off the paint clean the area then prime before bonding
Title: Re: Paul's 4thirty Build
Post by: Wizard on May 20, 2015, 07:04:53 AM
Daz, u started a build thread, tried looking but couldn't see it....?
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 24, 2015, 07:24:36 AM
So I did a proper road test yesterday. Probably drove 60+ miles, on all type of roads: fast, slow, smooth, rough and areas with speed bumps. I’m very pleased with the results. Gone are the nasty bangs that makes make you clench your teeth and car feels… well, just normal, like it always should have been like that. It doesn’t feel like a kit car, it feels more planted and stable. Don’t get me wrong, the ride is firm, and it isn’t super smooth, you feel the odd bump (this isn’t a Merc S-class remember! Lol) but it is much easier to drive. It used to be hard work driving it, always on edge thinking is that pot hole going to cause issues etc... I live in a village with lots of speed humps, and now it isn’t a case of slowing down to slower than a snail’s pace. It is much more practical to drive and live with. So happy days!

Part of my road test, was taking it to Andy’s (V8 KLR). As he helped me so much, I thought it only fair I let him have a drive and test it.  MY GOD, did he test it alright! I was sh#tting myself in the passenger seat whilst with a big grin on my face! He certainly drives harder than me! LOL. I think what we’re going do is uprate the front pads to green-stuff ones and also fit some braided hoses.

Thanks also to Rudy who sent me plenty of information on the suspension set up. I also checked the tyre pressures and fine-tuned these. Another excuse for a road test!

Here are some more pictures. Below is the front top of the suspension mounts showing the new coil overs with room for adjustment.

 (http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4813_zpsqzxcvcwa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4813_zpsqzxcvcwa.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4814_zps1y4faodl.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4814_zps1y4faodl.jpg.html)

Then I thought I’d put back the under bonnet cover. The slight issue there is the fact the new suspension bolt threads are higher than standard, so they can get in the way of the cover

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4815_zps7c07k0lq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4815_zps7c07k0lq.jpg.html)

So I put the cover in placed and pushed down on it, to make where he thread was, then drilled a hole so it could poke through and put a washer and nut on top. This acts like an extra fixing for the cover as well..

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4817_zpsg2eqyhjt.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4817_zpsg2eqyhjt.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4819_zpsh4rjo2vj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4819_zpsh4rjo2vj.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4820_zpsrpix1kms.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4820_zpsrpix1kms.jpg.html)

Here are some pictures showing the side profile now. The rear sits slightly higher than before, front is probably the same as before. 

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4840_zpsa34unyuq.png) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4840_zpsa34unyuq.png.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4828_zpszkhfybsy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4828_zpszkhfybsy.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4829_zpszxt1xpfx.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4829_zpszxt1xpfx.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4830_zpsmnp7mp1t.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4830_zpsmnp7mp1t.jpg.html)


Some more shots

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4822_zpsjsxkv4by.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4822_zpsjsxkv4by.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4824_zps0akqrobx.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4824_zps0akqrobx.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 24, 2015, 07:30:19 AM
Those of you with really eagle eyes probably noticed I don't have my under front-bumper cover on or lower front arch liners on the car at the moment. Well there is a very good reason for this, as I am currently working on my next project. A front-towing eye bracket set-up. Watch this space!  ;D
Title: Re: Paul's 4thirty Build
Post by: V8 KLR on May 24, 2015, 11:17:15 AM
Ha ha ;D...I was taking it easy Paul as it was your car................. :o...it did drive well though....
Title: Re: Paul's 4thirty Build
Post by: NYAL F430 on May 24, 2015, 04:17:22 PM
Great build Paul cars looks amazing on them coilovers :o, looks really genuine in them pictures
Title: Re: Paul's 4thirty Build
Post by: cheets on May 24, 2015, 07:06:36 PM
Nice to hear it better on coilovers can not what to get driving min :) was thinking of dining something for a front-towing eye but need to get it on the road first :)
Title: Re: Paul's 4thirty Build
Post by: Furrari on May 24, 2015, 11:21:27 PM
I had green stuff and braided hoses on my 430, it made a big difference to the feel of the brakes.

Most warranties run out after a certain time.  EBC warranties are different, they don't start until you have done 500 miles.  Mine sounded like nails down a blackboard for about the first 50 and not a squeak after that.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 25, 2015, 09:39:57 PM
Front Tow Eye 430

So as I mentioned previously, the next thing I have been working on is the front tow eye. This subject has come up before on the forum as there is no towing ability for the 430. I’ve thought about this many times, but never got around to doing it. But when I called in to see MADMAN on the way back from Woodsport and saw what he had done, it went right to the top of my to do list. So after chatting with MADMAN (a lot) and Wizard I’ve finally come up with this. I hope this is the simplest way to get around this issue. Fingers crossed it all works out.

I wanted to utilise the original mounting point for the MR2 tow eye that is a nut welded underneath the front bumper bar behind the 430 bumper. I toyed with adding a new mounting point to the bumper bar, but is would be very difficult to weld, especially with the 430 kit still on. The issue with using the MR2 mounting point is, if you wanted the tow eye to come straight out from this point you’d have to cut a hole in the bumper. That wouldn’t look good. So the way around it is to create a bracket lowers and moves the mounting point of the tow eye left so you can screw a towing eye through a hole in the grill. I would have to cut a small hole in the grill but then this could be covered up with a rubber bung/grommet and removed only if you needed to screw the external towing eye into it. (If that is a bit hard to follow, the pictures will explain all). To make this bracket I got a nice plate of steel 5mm thick and various other bits and bobs.


Here is the MR2 towing eye

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4841_zpstbxqmbfg.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4841_zpstbxqmbfg.jpg.html)


These are M16 nuts that are 10cm long. One of these would be welded to the bottom of the bracket for the external tow eye to screw into behind the grill.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4844_zpszkmu3lfd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4844_zpszkmu3lfd.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4845_zpsjui9ivnk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4845_zpsjui9ivnk.jpg.html)


I bought a universal external tow eye off eBay with an M16 thread below, however the gaps in the thread are too big (arrow below). This doesn’t matter really as I want to extend the length of the external tow eye anyway.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4850_zpsrq0hgnk5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4850_zpsrq0hgnk5.jpg.html)


Once it is all unscrewed, the hole size that feeds into the black part is an M12 thread. So I have bought some M12 threaded bar and an M16 threaded bar and together with a thread reducer, I will make a longer external tow eye that screws through the grill when needed.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4851_zpsgnvmwxu7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4851_zpsgnvmwxu7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4852_zpsinficp86.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4852_zpsinficp86.jpg.html)


So I started by making up a rough template out of cardboard. You need to do all of this with the front bumper on so you can get the right position.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4846_zpsvr046wms.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4846_zpsvr046wms.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4847_zpsxzhserda.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4847_zpsxzhserda.jpg.html)


Got the steel plate and started marking it all out

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4861_zps8lvtc6d3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4861_zps8lvtc6d3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4862_zpseoqfhugn.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4862_zpseoqfhugn.jpg.html)


I cut out 2 pieces as I originally planned to have 2 plates. I think now that I will only need 1

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4865_zpsfdhesyqi.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4865_zpsfdhesyqi.jpg.html)

Here you can see the MR2 tow eye in situ. When the tow eye is screwed in fully, as luck would have it, the angle of the hook bit if you at it straight on, is like the yellow line I have drawn. This is the perfect angle for the steel plate and you want it pointing down more like 5 o’clock not 6 o’clock

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4866_zpsloz2wazk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4866_zpsloz2wazk.jpg.html)


So when the steel plate is attached to the MR2 tow eye, you need to remember that the bumper bar nut is under the bumper bar, so you cannot weld the plate too far along the tow eye (towards the thread) otherwise you’d never be able to screw it is and it would bang on the bumper bar. So I marked a line where the steel plate could come up to.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4867_zpstufb8dsv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4867_zpstufb8dsv.jpg.html)


I thought about cutting off the hook part, but it is actually better to keep it on as it means there is more metal to weld to the plate. However I trimmed off some of the excess so the plate had more of the tow eye to butt up against.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4868_zpsii9he3wz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4868_zpsii9he3wz.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4869_zpsx01xy1gs.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4869_zpsx01xy1gs.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4871_zpsx9ew9sfb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4871_zpsx9ew9sfb.jpg.html)


So this is how it is all going to fit together

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4872_zpsjrclavqk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4872_zpsjrclavqk.jpg.html)


Weld the MR2 tow eye to the plate here

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4873_zpsullngubz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4873_zpsullngubz.jpg.html)

Then weld the long M16 nut to the lower part of the plate

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4874_zpsqq2gl8tz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4874_zpsqq2gl8tz.jpg.html)


So we have something like this

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4876_zpshyumggod.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4876_zpshyumggod.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4877_zpssdrwf1og.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4877_zpssdrwf1og.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4878_zpspxppegkh.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4878_zpspxppegkh.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4880_zps9yiuzehf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4880_zps9yiuzehf.jpg.html)


Here are all the measurements

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4882_zpsynasdaus.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4882_zpsynasdaus.jpg.html)


So I plan to take it somewhere to get welded up tomorrow. Once done I will spray it all black. Obviously to fit it you needed to remove the front bumper but with the bumper off I can do a proper road tow test. But this will be in a few weeks.
Title: Re: Paul's 4thirty Build
Post by: Furrari on May 25, 2015, 10:01:02 PM
Just put it through the grill on the centre line.  If anybody asks just tell them it's for the starting handle.  :-)
Title: Re: Paul's 4thirty Build
Post by: CdRsKuLL on May 25, 2015, 11:40:58 PM
Looking nice. Are you going to weld the original tow hook in place? The reason I ask is if you dont then any side force on the new one will undo the original one ripping your front bumper with it when it twists side-wards.

Also, if the towing hook is hardened due to the extreme force it's going to take, then welding it could remove the hardened properties. Not sure if these are hardened to be honest, just wondering.

Steve
Title: Re: Paul's 4thirty Build
Post by: cheets on May 26, 2015, 03:17:41 AM
Liking your work bud  :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 26, 2015, 05:52:19 AM
Thanks Steve. I know what you mean about the twisting. I hadn't planned to weld in place to the original nut on the bumper bar. I had thought about using some super high strength thread lock though.  Hopefully the bracket shouldn't twist as the force will be a pulling one on the bracket not a twisting one. This tow eye is only ever to pull the car onto a recovery truck. So in a straight line and not any great distance on the road. To actually fit the bracket in place I will need to remove the front bumper so I plan to do a test with it before putting bumper back. What do you and others think?

As for the whether they are hardened I have no idea but I will mentioned to the welders today.
Title: Re: Paul's 4thirty Build
Post by: MADMAN on May 26, 2015, 07:50:40 AM
Paul, I managed to fit mine with bumper in situ, I just removed plastic under tray.
MADMAN 8)
Title: Re: Paul's 4thirty Build
Post by: Furrari on May 26, 2015, 09:19:58 AM
If it's not a silly question, how do Ferrari do it on their road cars.?
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 26, 2015, 08:05:22 PM
Here is a real one - this is the same position i am going for
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 26, 2015, 08:13:13 PM
So good news on the welding. Dropped it off at a place local to me. Went thru everything with the guy there. He understood and got it all perfectly. He said it will be really strong. It wouldn't pull the QE2 but it would be close!  ;D. He asked what car it was for so I told him the whole story. He said come out the back and there was a GT40 replica frame and kit that he was working on for a customer. Nice. I said that is probably the next kit car I do, (not for a few years) and he said, well you know where to come for any welding.. LOL. total cost £15.
Title: Re: Paul's 4thirty Build
Post by: Furrari on May 26, 2015, 08:34:03 PM
It's a small world.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 29, 2015, 09:42:07 PM
Tow eye back from the welders. Very pleased with the results. It's proper solid. Wiill spray back tomorrow.
Title: Re: Paul's 4thirty Build
Post by: cheets on May 29, 2015, 10:02:58 PM
Nice work Paul can not wait to see it on the car :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 31, 2015, 06:58:00 AM
Painted it all up in black. As for fitting up to the car. will try next weekend
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 31, 2015, 07:30:10 AM
Centre Console

Those of you may remember, while my car was away at Woodsport, I had a go at trying to make a new centre console. I cut the top off an old MR2 one and built a new wooden one to go on top. It was ok, but tbh it would be better to do away with the whole MR2 console and built one from scratch. I had put the project on the back burner, but then I bumped into my mate Barry last weekend, who told me he was going to make a new one, so he spurned me on to take a look at the project again.

While the car was at Woodsport, they took the MR2 console out, and when they put it back I asked them not to bother putting the 2 screws that go at the front of console back in place. To get to these you really need to take the seats out and I didn’t want to have to do that. So the other night I bit the bullet and removed it all to see what is below it all.

This is what is below:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7421_zpsrd8sztd6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7421_zpsrd8sztd6.jpg.html)

At the black arrow you can see that the MR2 gear stick has a bend in it. Not much but it would spoil the look, especially if you are having an H-Gate like I plan to do. I have thought about this a lot, and Barry and I are going to have this part straighten up by our local garage. (I will let Barry go first to see how it turns out, but it should be fine! LOL) Then Barry had the idea of covering the stick with some shiny chrome pipe that people put around radiator pipes when they have laminate flooring done to make the radiator pipes look more attractive. It will also hide any slight imperfections in the stick from the straightening out

I probably won’t use this exact H Gate (Thanks Wizard for the loan of yours while I try this all out). I got Woodsport to make the gear linkages/shift pattern as small as possible so the stick moves around the in gap in the centre, short shift style to avoid the stick having to go in and out of the slots.

At the yellow arrow, this rubber part of the handbrake lever, I will cut away as I plan to have a leather gaiter here instead. I am not going done the route of moving the handbrake over to one side as I don’t want to change things too much mechanically.

At the blue arrow, you have these cables. Because of these, the new console has to rise at the rear to cover these and ensure it butts up to the carpet. This means my first attempt a few months ago wouldn’t have worked as I had it flat all the way to the back.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7422_zpsuukabk3h.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7422_zpsuukabk3h.jpg.html)


So the sort of look I am going for is below. This is a real F430 centre console with a gear shift.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7424_zpsb8sqazv2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7424_zpsb8sqazv2.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7424-2_zps2dvgaxv7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7424-2_zps2dvgaxv7.jpg.html)


The main height of the console will be governed by the handbrake lever. With the lever in the off position you want to be able to get your fingers around the bottom of it. The gear stick part with then come higher and I will have the silver box part to raise it slightly and then the H-Gate on top. So here is my attempt at the template made out of cardboard yesterday morning.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7444_zps21didbwx.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7444_zps21didbwx.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7446_zpsecp4jibm.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7446_zpsecp4jibm.jpg.html)

Here you can see how it has to go up at the rear to clear those 2 cables

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7445_zpssygmlpe2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7445_zpssygmlpe2.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7447_zpsoiten400.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7447_zpsoiten400.jpg.html)


Here is the clearance for the handbrake lever

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7448_zpse2hizxyc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7448_zpse2hizxyc.jpg.html)


And this is what it looks like outside of the car

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7449_zpscsjlsaic.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7449_zpscsjlsaic.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7450_zps5zrx98co.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7450_zps5zrx98co.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7451_zps0blpq4z7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7451_zps0blpq4z7.jpg.html)


So it is off to Wickes/B&Q this morning to get some wood to start making it all up for real.  ;D ;D ;D
Title: Re: Paul's 4thirty Build
Post by: beemaman on May 31, 2015, 09:20:51 AM
Wicked job Paul can't wait to see it finished :)
Title: Re: Paul's 4thirty Build
Post by: ferrari feb 14 on May 31, 2015, 10:47:06 AM
Great start Paul ,I'm sure this will turn our fantastic like everything else ,cheers jd.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on May 31, 2015, 08:57:56 PM
So after getting some MDF I started to build the real thing. For the sides I used 3mm and the top I used 6mm. It is a lot harder building out of wood compared to cardboard. Cardboard is obviously much more flexible and moves without you realising it. The main thing that I had to do was to build a slight slope into the sides parts. To fix the whole thing together I used baton to screw the pieces together and it gradually took shape. Plenty of test fitting along the way in the car and I got there in the end. To create the slopes on the side, I packed the pieces out with washers (see the photo with the red arrows). Once I have it 100% I will stick a small line of stikaflex along the gaps to keep it all in place.  The pictures say a 1000 words so I’ll let them do the talking. I'm pretty pleased how it turned out in the end.  :)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4933_zpsksunx3mk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4933_zpsksunx3mk.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4937_zpsmzupfi5e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4937_zpsmzupfi5e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4938_zpslxhnlcwm.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4938_zpslxhnlcwm.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4936_zpswyggjbgm.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4936_zpswyggjbgm.jpg.html)

Here to can see the slope I managed to achieve on the side parts

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4939_zpsn7vj3yxt.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4939_zpsn7vj3yxt.jpg.html)


So this is how far I got:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4935_zps15pc90ow.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4935_zps15pc90ow.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4940_zps0tke56qw.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4940_zps0tke56qw.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4941_zpsiigyvfdd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4941_zpsiigyvfdd.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4942_zpsebgs4ql1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4942_zpsebgs4ql1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4943_zpsehkgdvet.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4943_zpsehkgdvet.jpg.html)


View from the front – just need to fix the plate for this and then the basic construction is done

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4944_zpsi08nfxsa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4944_zpsi08nfxsa.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4945_zps9tgahiyj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4945_zps9tgahiyj.jpg.html)


Here is the handbrake fully off – plenty of room for the fingers.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4946_zpso2em33jw.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4946_zpso2em33jw.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4947_zpsng12aptm.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4947_zpsng12aptm.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_4948_zpsc9otzdz0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_4948_zpsc9otzdz0.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: beemaman on May 31, 2015, 09:16:54 PM
Great work Paul as always buddy first class mate :)
Title: Re: Paul's 4thirty Build
Post by: Furrari on May 31, 2015, 11:09:39 PM
Your skills exceed my wood butchery.
Title: Re: Paul's 4thirty Build
Post by: Lee22 on June 01, 2015, 01:31:57 PM
Looking great Paul,

Just one question mate..!

I only see 1...??

Where's mine?

Are you ironing out all the issues first before you start on 'Version 2' for me.. ;D

LeeC
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 02, 2015, 07:20:39 PM
Lol. Sorry Lee. I've got my work cut out with just one console. I'll take down the measurements for you if you like. 😀
Title: Re: Paul's 4thirty Build
Post by: Lee22 on June 03, 2015, 01:25:53 AM
All the measurements you can Paul please.

Plus, keep the cardboard one on one side...... ;D don't throw it away.....

Thanks

LeeC

Ps - more pictures please.... :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 03, 2015, 06:40:11 AM
No probs Lee. I'll keep the cardboard one for you. Here are some more pictures

I have decided to get the gear stick straightened. My mate Barry had this done yesterday on his car and is very pleased with it. Took a couple of hours. I have also decided to do away with the extra silver bit that goes around the bottom of the gear stick as it isn't needed. I have raised the console up slightly so it is flush so the h gate sits on the main console.

The next dilemma is the handbrake gaiter. I've discussed various options with Wizard. This issue is the hole for the handbrake has to come this far forward to allow the console to be fitted. But you wouldn't want the gaiter to cover all this hole up as it simply won't work when the handbrake is put down. So o think the only way to do it is to have the gaiter attached from the inside of the console and then then bottom and then a plate covered in leather to hide the hole at the front of the handbrake.

I bought this blue one just to try out. If happy I will have it made in the same colour as the seats.

Title: Re: Paul's 4thirty Build
Post by: cheets on June 03, 2015, 10:02:32 PM
Nice work Paul can not wight to see it covered :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 04, 2015, 06:57:53 PM
I've thought alot about the window switches on the console. My initial thought was to get new ones that would fit into a hole on the top part of the console. However I don't fancy trying to wire them up so decided to keep the mr2 ones. But this left a problem of how to mount them. I've decided to cut 2 rectangular holes on the top and the mount the switches from underneath. But I wanted to line the hole with something. Looked on eBay and found these silver things. They are surrounds from a BMW hazard switch. The plan is to line the hole with these like below.

They are a little big but they give enough room for the fingers and when mounted no daylight will show thru from underneath. Could even hide the gap with black plastic.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 04, 2015, 07:03:25 PM
Yesterday I finished off the wood work on the console. Added the front plate. So now the front rests on the carpet and raises the h gate part just enough to clear the white part at the bottom of the gear stick. Placed the silver surrounds where the window switches will go and tidied the hole for the handbrake gaiter.
Title: Re: Paul's 4thirty Build
Post by: cheets on June 04, 2015, 07:12:58 PM
Nice work Paul are you leaving the H gat on the centre console or are you lifting it off ?
Title: Re: Paul's 4thirty Build
Post by: beemaman on June 04, 2015, 07:16:11 PM
Looks great Paul that's great work buddy :) will look perfect when trimmed.
Title: Re: Paul's 4thirty Build
Post by: ferrari feb 14 on June 04, 2015, 07:51:31 PM
Coming along nicely Paul ,window switches look great ,jd
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on June 04, 2015, 08:00:43 PM
Looking great mate.
Title: Re: Paul's 4thirty Build
Post by: Ronan7051 on June 04, 2015, 08:03:57 PM
Looking good Paul, nice work as always.
Title: Re: Paul's 4thirty Build
Post by: MADMAN on June 04, 2015, 11:51:52 PM
Looking good Paul,
                       I found mine to have insufficient room under handbrake for fingers, so I used the recess on the rear of the OEM console cutting it to size and bonding it in place ( could be my thick fingers) lol
MADMAN ;) ;) 
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 05, 2015, 06:42:09 AM
Nice work Paul are you leaving the H gat on the centre console or are you lifting it off ?


Cheets. I was going to leave it flush on the centre console but last night decided that I do need to raise it. I need to create an illusion of depth below the h gate because at present the white at the base of the gear stick is flush with the wood. I will build up the height of wood via mdf. Not a separate silver piece like on the real car. The raised part will still be covered in the leather. I will paint the white plastic part at the base of the gear stick black so less shows thru.

Guys - thanks for all the kind comments and encouragement. There's been plenty of head scratching and plenty to do but I'll get there.
Title: Re: Paul's 4thirty Build
Post by: V8 KLR on June 05, 2015, 12:53:31 PM
Paul does the gear stick miss all the parts of the H gate when you change gear? Raising the H gate may increase the amount of "throw" which could man the gear stick catches the H gate... but trial and error I reckon. If it works I think I will put the H gate on top of my standard console.
Title: Re: Paul's 4thirty Build
Post by: cheets on June 05, 2015, 06:13:40 PM
Yes that is what i was thinking Paul as well going of what madman sed you if you was catching your hand wen using the hand brake you can drop the console  done a bit

Mark :)
Title: Re: Paul's 4thirty Build
Post by: MADMAN on June 05, 2015, 11:42:23 PM
I've thought alot about the window switches on the console. My initial thought was to get new ones that would fit into a hole on the top part of the console. However I don't fancy trying to wire them up so decided to keep the mr2 ones. But this left a problem of how to mount them. I've decided to cut 2 rectangular holes on the top and the mount the switches from underneath. But I wanted to line the hole with something. Looked on eBay and found these silver things. They are surrounds from a BMW hazard switch. The plan is to line the hole with these like below.

They are a little big but they give enough room for the fingers and when mounted no daylight will show thru from underneath. Could even hide the gap with black plastic.
Look good Paul, what is the dimensions of them?
cheers MADMAN
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 06, 2015, 11:08:08 PM
Steve, i'd say measuring them, the hole that they would fit would be 58mm by 26/27mm - by that i mean the hole in a flat piece of wood/plastic that you sink them into.

from looking down at them from the top the area is smaller. the standard mr2 window switches definitley fit


here is the ebay item i bought: http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItemVersion&item=371327905046&view=all&tid=723910844024

Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 06, 2015, 11:23:12 PM
Did a bit more work on the console tonight. As previously mentioned I added a new top plate to the area where the gear stick goes into. I shaped it with a slope at the front and back. This is probably enough to create an illusion of depth below. Then I marked out the h gate and re cut the hole.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5026_zpsf9vts7y3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5026_zpsf9vts7y3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5027_zpsiuwwvmsu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5027_zpsiuwwvmsu.jpg.html)

I tried it on the car and all fine. However since then I have decided that I am going to use the H-gate you see in the pictures. Previously the plan was I was going to get one made up especially, but after trying some templates from pictures on the internet I don’t think they would work (Saved you some work there JD LOL!) My gear shift is basically a short-shift, because I specifically asked Woodsport to make it like that when they were doing the V6 conversion, so I need the area in the centre to be as big as possible. I am going to have to trim down ever-so-slightly the metal slits so the gear stick doesn’t hit them but it will be a case of making them a square end as opposed to a curved end. It should be fine. BUT the hole in the wood I have cut too big again for the H-gate to be mounted with a screw in each corner, so tomorrow I will make another top plate with a smaller square in the centre so the H-gate has enough wood to mount against.

I then cut the holes out for the window switch surrounds

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5028_zpsypv9nxxy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5028_zpsypv9nxxy.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5029_zps2cbvdjsx.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5029_zps2cbvdjsx.jpg.html)

These have plenty of room to account for the leather once it is trimmed
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 06, 2015, 11:32:36 PM
For the handbrake gaiter I have done some more playing around with the blue one. It is fitting better but is not perfect. There is too much material there for it to look neat so I am going to make my own template. My Mum is bringing over her sewing machine tomorrow so I am going to have a go at making one that fits better and will do away with he need for a plate to cover the gap at the front of the handbrake hole. It will probably take a few goes but I am sure we'll be able to get something that fits.

BUT the final question is what colour to do the console? Originally I thought beige to match the seats, but I am now thinking of doing it black with red stitching. The reason being is:

it will make the chrome bits stand out more
it will hide any imperfections in the console
my dash will be black with red stitching so it will match that
below the h -gate if it is black it will look less obvious it isn't real as it will all be dark/black down there


what do you all think?  :-\
Title: Re: Paul's 4thirty Build
Post by: Furrari on June 07, 2015, 09:49:41 AM
If you use the same as the seats you see a sea of the same colour when you look in.  On The Furrari the consol sweeps down from the dash so it's in the same material as the dash and has the same (yellow on black) colour stitching.  IMHO this looks classier.  The down side of this is that because it's contrasting any errors in the stitching stand out far more.

On the door cards of The Furrari it was my intention to have the stitching across the centre of the air bag blow out panel in yellow but the needle followed the holes in the perforated leather and it was impossible to keep it straight.  In black stitching it still follows the holes but now it doesn't stand out as a crooked line.

Don't you find the small detail decisions and executions of them difficult.  If you get it right nobody but us will ever notice.  If you get it wrong nobody but you will notice because the eye sees what the eye wants to see but it will bug you until you get how you want it to be.

PS if all else fails I can see you've been trying it out as a window box.  :-)
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on June 07, 2015, 10:41:16 AM
I think black with red stitching. But you might consider, black top, beige sides and red stitching.
Title: Re: Paul's 4thirty Build
Post by: ferrari feb 14 on June 07, 2015, 10:53:03 AM
Hey Paul looks sweet mate ,what about filling the screw holes over and getting it carbon dipped, just a thought , jd
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 07, 2015, 07:55:00 PM
thanks for all your advice guys. I think it has to be black with red stitching then. My Dad said this aswell as it create a contrast and matches the rest of the dashboard.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 07, 2015, 08:00:30 PM
So last night I took some photos of the MR2 console next to my new one. The overall dimensions look very close, so I am very pleased.  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5032_zpscbtmqh4e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5032_zpscbtmqh4e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5033_zpsiquhawff.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5033_zpsiquhawff.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5035_zpshjyhxgxs.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5035_zpshjyhxgxs.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5036_zpshtrurhnc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5036_zpshtrurhnc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5037_zpsd43dn3np.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5037_zpsd43dn3np.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 07, 2015, 08:17:24 PM
So today I worked on the mounting of the window switches. I used black con blocks and screwed them to under side of the top at either end of the window switch holes. I did this so the switch could clip up against them like they do on the MR2 console. I used countersunk machine screws and bolted them in. The blocks lower the amount of actual switch poking thru. I could have gone lower but I am happy with how they sit.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5042_zpsbtpo9y7y.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5042_zpsbtpo9y7y.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5046_zpsonzrfykd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5046_zpsonzrfykd.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5043_zpsxhlwpfla.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5043_zpsxhlwpfla.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5044_zps4zjw1o7v.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5044_zps4zjw1o7v.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5045_zpskhdvh7zt.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5045_zpskhdvh7zt.jpg.html)

The next issue is although the switches won’t come out if pushed from the underside, once depressed they could slip back down into the hole. So I made bracket that stops this happening and is bolted from the underside, so it is all fully removable. Pictures explain all.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5047_zpsdlon2xal.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5047_zpsdlon2xal.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5048_zpsjyd9l6hr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5048_zpsjyd9l6hr.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5049_zpsyuawznp7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5049_zpsyuawznp7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5050_zpsplspvgvn.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5050_zpsplspvgvn.jpg.html)

This fixed the switches falling thru the hole from the front, but I still want to secure them from the rear, if somehow they we pushed down from the rear. I couldn’t do the same type of bracket for this as the connection points on the switches is different for the drivers vs. the passenger. On is right at the back of the switch while the other in the middle!

Then I had a great idea. The raised plate that I have to redo that goes below the H-gate I took off and cut in two. I then screwed one half from underneath and this works perfectly as a brace and is fully removable also. See picture below with the arrow

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5054_zpstjihqfos.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5054_zpstjihqfos.jpg.html)

I have since discovered, that the first bracket I did, won’t work as it stops the console being mounted properly when on the car. There are some wires that the bolts for the bracket catch on. But no worries,  I will do the same with the front by using the other half of the faulty raised plate! Simples. I just need to get shorter machine screws for the con blocks and then all will be well. So this is how it all looks with the switches.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5052_zpsopnm8ddp.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5052_zpsopnm8ddp.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 07, 2015, 08:39:35 PM
So the last big job was the handbrake gaiter. Recall I had bought this blue one off eBay to chop around with.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5015_zpsqek6kipf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5015_zpsqek6kipf.jpg.html)

However, I knew if this was going to work I would need to make my own.  So using the blue one as a base, I cut one my own one adding more material at the front to cover the hole in the console. My Mum brought her sewing machine and quickly sewed it up. I thought we would have to make multiple versions but we got it right on the 2nd attempt. Cheers Mum! So I will just get the shape made up in the same leather and staple it in once done.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5056_zpstzm3wsn9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5056_zpstzm3wsn9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5057_zpsnie9oumn.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5057_zpsnie9oumn.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5058_zps9cfnv1ud.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5058_zps9cfnv1ud.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5059_zpsoy9n4tde.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5059_zpsoy9n4tde.jpg.html)


Front gap now covered. I don’t think we could get it much better than this!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5060_zpswsnavbfa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5060_zpswsnavbfa.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Phils99 on June 08, 2015, 12:33:45 PM
brilliant as always...gives me some ideas on how to secure my window switches in my OEM console....
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 09, 2015, 06:37:20 AM
On the home straight now. I've done the front switch support bracket last night and redone the top plate for the h gate. Going to use m3 Allen bolts to bolt the h gate to the wood. All on order from eBay. It's booked to go to the trimmers on Saturday so better get a move on! Here's some pictures.
Title: Re: Paul's 4thirty Build
Post by: Lee22 on June 09, 2015, 07:49:45 AM
Looking good Paul.

Can't wait to see the finished masterpiece.. ;D
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on June 09, 2015, 02:07:17 PM
Looking good mate.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 12, 2015, 10:07:36 PM
Console all done. Had to make the top plate again for the 3rd time as hole I cut was still too big. But all good now. Tried out the h gate and drilled holes for it to bolt to the top plate. I will use 4 Allen bolts to attach it. Drilled the holes in the sides to allow it to be secured to the mr2 original fixings. Filled in any chipped bits on the wood and rubbed down. Bonded it all up on inside. Fitted switches all back and fitted all up to test it all. All fine. Off to the trimmers in the morning (much to the relief of my long suffering wife! - don't worry Jules, there's the dash to do next! And the tow eye, brake pads/hoses etc.... 😊). Here's some pictures.
Title: Re: Paul's 4thirty Build
Post by: MADMAN on June 12, 2015, 10:21:21 PM
Looks like to many Stella,s before you cut out where the H gate fit,s  ;D
MADMAN ;) ;)
Title: Re: Paul's 4thirty Build
Post by: 360MKbuild on June 12, 2015, 10:21:51 PM
Looks brilliant, as always. Can't wait to see it all leathered up. Still sticking to black? :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 12, 2015, 11:08:35 PM
Steve - it's isn't the Stella's, I just get excited with a jigaw - and I am not talking about one of the girl's puzzles! LOL  ;D
 
Mark - yep, still going for black nappa leather with red double stitching. That what the dash will be when I get around to it, but that not for a while yet  ;)
Title: Re: Paul's 4thirty Build
Post by: cheets on June 13, 2015, 04:00:44 AM
Paul all looking good was just thinking wen you do the dash were you going to put the hazed switch ?
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 13, 2015, 07:11:58 AM
thanks Cheets. dont get me thiunking about that! I'm not allowed to do the dash yet!  ;D.. i'll probably put it on the dashboard, next to the LED for the alarm. there's a coin tray thing i think there that I can get rid of. will try and go for a different shape hazard switch. has anyone got a picture of the reverse of a MR2 one? how many connections are there?
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 13, 2015, 05:32:51 PM
So I dropped the centre console off at the trimmers today. All good. I am going for Matt black nappa leather with red double stitching. Same leather as my steering wheel airbag. 3mm foam underneath as well. Should be done in a week or so. The leather will look like the side part of this seat in the picture below. Will have the gaiter done aswell in the same style with a rounded top.
Title: Re: Paul's 4thirty Build
Post by: cheets on June 13, 2015, 05:55:48 PM
That is ok bud just had a look and no pics of the hazed switch but this mite help you
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 13, 2015, 10:13:25 PM
Thanks Cheets. Will have a look.

Quick tow eye update. The connector I ordered ages ago finally turned up this week. This converts an m16 thread to a m12. Pictures below. I will shortened the m12 thread into the tow eye and then just have the m16 direct into the bracket. It is probably best to have the whole thing poking forward when in use so it clears all of the front bumper to avoid any potential damage.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 14, 2015, 09:11:03 PM
Not a lot done today car wise. I actually did quite a few miles in the car this weekend despite the weather. Just trimmed down the m12 thread and then thread locked the tow eye all together so now it looks like below. I'll probably keep it all this length so it clears the bumper nicely when installed.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 15, 2015, 08:51:36 PM
So I ran into a bit of trouble last week with the h gate. When trying to drill the holes I simply could manage to do it. I got 2 and a half done and then gave up. The drill had hit too hit and hardened the steel in places.  I thought I had ruined it. So I asked JD for some advice. He very kindly offered to have a look and fix and polish it. So I popped in the post Friday morning and at lunchtime today I got the text to say it was being worked on. What a great guy. Then before home time another text with it looking a million dollars. Thanks ever so much JD. I owe you one. I'm so happy. It looks brill especially as i thought I had ruined it. Cheers

Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 16, 2015, 06:50:35 PM
QUESTION GUYS

does anyone know whether the dash boards on the mr2 mk3 are the same pre and post facelift?
Title: Re: Paul's 4thirty Build
Post by: DNA AUTOMOTIVE on June 16, 2015, 07:21:51 PM
different radios thats all I think
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 19, 2015, 06:34:29 AM
H gate back from JD. Looks awesome. Thanks ever so much JD. You're a life saver. 😀
Title: Re: Paul's 4thirty Build
Post by: ferrari feb 14 on June 19, 2015, 08:50:11 AM
No probs Paul pleased your happy with it ,can't wait to see it on the new console when are you expecting it back ,jd
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 19, 2015, 08:34:47 PM
Should be ready next weekend. No rush tbh. Car has MOT on Monday and will get the gear stick straightened then aswell.

Has anyone had any plastic chromed before as I am thinking getting the outer rings for my air vents chromed when I finally do the dash.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 20, 2015, 09:10:29 AM
Once the gear stick is straight I plan to cover it with this copper pipe that has been chromed. I tried it out last night. Any thoughts on the gear stick height? Lol! Seriously. On the base part of the gear stick it fits lovely.
Title: Re: Paul's 4thirty Build
Post by: Wizard on June 20, 2015, 11:42:48 AM
Your car certainly will be very unique and original. If you add a satellite dish on top of the gear stick I think you can make contact with the aliens.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 22, 2015, 04:56:09 PM
Been a busy few days on the car doing a few jobs. In preparation for the cars MOT, I checked all the lights. It turns out the 3rd brake light wasn’t working. Checked fuse and all fine, so I took the light out and it had come unconnected. Doh! Anyway I remember when building the car I just couldn’t find the right plug that would go with the brake light so in the end I managed to put some spade connectors on but I was never really happy with it. And now it shows that they weren’t good enough.  The 2 prongs sticking up inside the light are very fiddly to get the connectors on so I decided to improve things.

I took the whole thing apart and soldered some wires onto it and then fed these through the hole. I sealed it all up to keep the wires still and also to stop moisture getting inside. Then I added better connectors at the end of the wires so the thing can be connected easier when put back onto the car.

Oh and also, while I was at it, I changed all the bulbs for some LED’s I had spare and now it is a lot brighter!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5206_zps5o6xi90r.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5206_zps5o6xi90r.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5207_zpslphfz43n.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5207_zpslphfz43n.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5208_zpskbd2fqkh.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5208_zpskbd2fqkh.jpg.html)


Soldered wires

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5212_zpsho6ej4gt.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5212_zpsho6ej4gt.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5210_zpssi9ys9bj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5210_zpssi9ys9bj.jpg.html)

LED’s

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5213_zpsb8fvqmlk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5213_zpsb8fvqmlk.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5220_zpsnsqdtjbf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5220_zpsnsqdtjbf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5221_zpsgmpuhqhm.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5221_zpsgmpuhqhm.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5222_zps1o5zv2pb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5222_zps1o5zv2pb.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 22, 2015, 05:25:17 PM
As a father’s day treat to myself I have also started on the dash. I got it out of storage and had a look at all the pieces and how they fit together.  I also looked and Phil’s build for details as he’s done a great write up there. (Cheers Phil)

Here’s the vent in 4 pieces. To pull the centre bit out, turn it at this angle like this and pull and it will pull out. The rear part locks together but they may be glued slightly so cut away the glue and then you can unlock them and it will come apart.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5277_zpsenefh7en.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5277_zpsenefh7en.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5278_zpsq9hbjrg0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5278_zpsq9hbjrg0.jpg.html)


As per Phil, you need to file down the lugs that stick out here so they are flush. Otherwise the vent wouldn’t fit in the hole you need to cut out

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5279_zpssgg0fbur.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5279_zpssgg0fbur.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5280_zpsmcnwkntl.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5280_zpsmcnwkntl.jpg.html)


Here are all the dash pieces, so I started on one of the side vents and cutting the hole to put the vent in

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5237_zpshucrufws.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5237_zpshucrufws.jpg.html)


I found the best way to do this as they are an awkward shape to hold them in a vice at the end with the larger piece of fibreglass (use blocks of wood so the vice doesn’t mark them) and then use a power file and sink into the fibreglass to create a hole to put the jigsaw through. Don’t try and drill a hole as it is too violent and could crack the fibreglass. Then use a small jigsaw blade as it is more nimble to cut around to get the majority of the hole cut. Then back to the power file and gradually make the hole bigger, testing each time and eventually the vent will fit. Screw the outer ring onto the piece you filed the lugs off and get it fitting so the outer ring hits the edge of the fibre glass. Simples.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5238_zpsvswptayc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5238_zpsvswptayc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5239_zps2frk1r6n.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5239_zps2frk1r6n.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5240_zpsj3alm5ht.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5240_zpsj3alm5ht.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5241_zpsxu9mexma.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5241_zpsxu9mexma.jpg.html)

Managed to get all vent holes cut and started on the larger hole down below

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5275_zpsd9x8dnum.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5275_zpsd9x8dnum.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5276_zpsr1rrvwkb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5276_zpsr1rrvwkb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5274_zpshxzvk64m.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5274_zpshxzvk64m.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: cheets on June 22, 2015, 05:43:23 PM
Nice work bud what bulbs did you get for the brake light ?
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 22, 2015, 05:47:44 PM
Cheets - They were LED's I had from a MR2 dash kit. A while ago I tried to change the speedo bulbs to white LEDs ones to try and make the light white behind the dails. but it didn't work as the speedo dials still had coloured film on so it made no difference. It was just on the off-chance yesterday I remembered I had them and thought they might fit and they did!  Woo Hoo ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 22, 2015, 05:48:53 PM
So today the car had its MOT. Sadly it failed, but only on a blocked washer jet and the rear tyres. Basically due to the low profile (35) and the harder suspension the wall had started to split on the insides. No problem really as I wanted to change the tyres anyway – now I have to! Not sure of the make on there at the moment, but will get a nice set of premium ones, such as Goodyear, Pirelli or Continentals.

So after the MOT I left the car and they straighten out the gear stick ready for the centre console. They also added the chrome tube for me as well.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5255_zpswriag6yl.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5255_zpswriag6yl.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5254_zpsxhrya2sr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5254_zpsxhrya2sr.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: beemaman on June 22, 2015, 07:16:35 PM
Great work Paul as always :) nice little touches can't wait to see console buddy fitted
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 22, 2015, 07:26:31 PM
So as I had the day off for the MOT, I thought I’d make the most of it try and fit back the tow eye bracket. The first job was to take front bumper off to screw the bracket in place.


(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5256_zpsxdrpvvva.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5256_zpsxdrpvvva.jpg.html)


As an aside here is a shot of the nice big radiator Woodsport added when doing the V6

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5257_zpsjpwwksc0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5257_zpsjpwwksc0.jpg.html)


Here is the original MR2 nut that the tow eye is screwed into

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5259_zpsqavhyoie.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5259_zpsqavhyoie.jpg.html)


Added the bracket and got it in position. It wasn’t perfect, so we had a think and spaced it out from the rear so that when screwed in it was in the right position. It needs to be pointing around at 5 o’clock when looking from the front in order for it to come through the grill. Basically behind the nut on the bumper bar is a piece of metal that the screw thread buts up against. By packing this out so the thread didn’t go in as far we managed to get it right.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5262_zpslhp4tb3d.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5262_zpslhp4tb3d.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5263_zps5cas6gis.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5263_zps5cas6gis.jpg.html)


Added the tow eye I had prepared earlier

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5264_zpsmosttled.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5264_zpsmosttled.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5265_zpsw7shmgvc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5265_zpsw7shmgvc.jpg.html)


Then we did a road test with the bumper off. We used my Merc and went around the block. It all held fine, BUT as we were basically going around a roundabout and turning right and the Merc tow eye was on the opposite side of the car to the 430 side,  the tow eye tighten further and spun to more like 7 o’clock. However as this is only designed to allow the car to be winched onto a trailer and the winch would be in the centre of the truck and we’d only be going in a straight line I think this would work just fine.  Before fitting the bumper back I took it all off and thread locked with the high-strength stuff.


(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5266_zpszf5lyrfi.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5266_zpszf5lyrfi.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5267_zpsd0nvw96u.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5267_zpsd0nvw96u.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5268_zpsvcxlxtve.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5268_zpsvcxlxtve.jpg.html)


So then it was back on the drive and time to put the bumper on. I pushed a bit long drill bit though the bracket so I could see exactly where the hole needed to be in the grill. I thought about drilling it but instead I carefully used small wire cutters to gradually cut out a hole. Because of the way the grill goes I made a diamond shape. I will cover this up with a bung of some sort

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5269_zpscn0rvskz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5269_zpscn0rvskz.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5270_zps1lejkibp.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5270_zps1lejkibp.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5271_zpsfqmrj7fv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5271_zpsfqmrj7fv.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5273_zpsoi5nz1y2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5273_zpsoi5nz1y2.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5272_zpsvbilgtbt.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5272_zpsvbilgtbt.jpg.html)

and there we have it - I hope I never have to use it!
Title: Re: Paul's 4thirty Build
Post by: Phils99 on June 22, 2015, 07:35:48 PM
Nice one mate!

All that work on something you hope never to use!!!!!
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on June 22, 2015, 10:02:53 PM
Nice work Paul.
I've done something very similar on mine and even though we all hope that we might never need to use it, it's good to know that it's there if needed.
With our cars it could be something very simple but will need recovery.
When I broke down last year, I wish I had it than as it was a nightmare to get the car on a recovery low loader.
I finished off the hole in the grill with a rubber grommet and looks good as a final touch.
Title: Re: Paul's 4thirty Build
Post by: 360MKbuild on June 22, 2015, 10:51:23 PM
Brilliant work as always :)

Another job to add to my long list from your build, too many good ideas  :)
Title: Re: Paul's 4thirty Build
Post by: Lee22 on June 23, 2015, 11:38:33 AM
So are you leaving the mesh with a hole in it Paul? Or are you looking at putting a rubber grommet in the cut out section.?
Title: Re: Paul's 4thirty Build
Post by: Lee22 on June 23, 2015, 11:44:40 AM
Paul
If the tie eye does move from 5 o'clock to 7 o'clock when the car is being pulled, are you not worried this could make a hell of a mess of the front bumper?

Is it not worth welding the new bracket to the original tie hole to stop this new bracket turning to 7 o'clock?

Just a thought?
Lee
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 23, 2015, 02:42:01 PM
So are you leaving the mesh with a hole in it Paul? Or are you looking at putting a rubber grommet in the cut out section.?

it will be covered with something yeah
Title: Re: Paul's 4thirty Build
Post by: MADMAN on June 23, 2015, 08:09:36 PM
So are you leaving the mesh with a hole in it Paul? Or are you looking at putting a rubber grommet in the cut out section.?

it will be covered with something yeah
I had a spare wheel cover lid that I cut the letter T from it and bonded it to a felt tip pen cap that fits into the nut that holds the tow eye. It then fell out, so I fixed it in with two tie raps that can be snipped off if and when needed
MADMAN 8)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 25, 2015, 10:32:36 PM
Here's my solution to the hole issue. I used a piece of spare mesh. Sometimes the most obvious ideas stare you right in the face. Lol. You can hardly see it now.  ;D
Title: Re: Paul's 4thirty Build
Post by: Lee22 on June 25, 2015, 10:39:27 PM
Fantastic Paul !  ;D

Well done mate
Lee
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 26, 2015, 07:01:53 AM
had problems loading the other photos up - here's the better ones
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 26, 2015, 07:04:42 AM
more
Title: Re: Paul's 4thirty Build
Post by: MADMAN on June 26, 2015, 10:28:56 PM
Excellent
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 27, 2015, 06:50:37 AM
So I have also been doing a few other bits and bobs during the week in preparation for the centre console coming home. I’ve decided that beneath the H Gate I wanted to see mechanical bits as I think this makes it more realistic as opposed to having a blanking plate of some sort, directly beneath the gate. However I wasn’t happy having the white of the gear shift structure showing so I decided to black all that area black. I thought about painting with a brush, but best way would be spraying. It takes a brave man to spray the inside of a Ferrari but it was ok in the end! LOL

So here is my masking up of the inside – nice new interior isn’t it!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7832_zpsy5hderxr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7832_zpsy5hderxr.jpg.html)


Everything was covered except the gear shift area

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7833_zpsgplqmcd7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7833_zpsgplqmcd7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7834_zpsrdwmt4l0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7834_zpsrdwmt4l0.jpg.html)


So I primed it, and then painted it all satin tough black

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7842_zps5dpppym6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7842_zps5dpppym6.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7851_zpsik2ysi8t.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7851_zpsik2ysi8t.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7856_zpsqrd8zwrf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7856_zpsqrd8zwrf.jpg.html)


Then I tried to paint the original stick chrome. It came out ok in the end but does show any imperfection in the stick.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7862_zpsrdao6cki.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7862_zpsrdao6cki.jpg.html)


I still need to decide on what to do about the silver tube. My issue is the tube makes the stick fatter and thus would knock the H Gate when changing gears. Anyway here is it all done with the tube on

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7877_zpsj24gqlv1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7877_zpsj24gqlv1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7878_zpsvw2au8p9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7878_zpsvw2au8p9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7879_zpslzj5d1iu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7879_zpslzj5d1iu.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 27, 2015, 07:08:14 AM
So Dad very kindly picked up the centre console for me on Friday. I was going to go a get it today, but I just couldn’t wait, so he brought it round in the evening yesterday. I am really pleased with it. It looks ace.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7880_zpsalml14nv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7880_zpsalml14nv.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7881_zpsw6wgxiht.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7881_zpsw6wgxiht.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7882_zpsoadiuwcz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7882_zpsoadiuwcz.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7883_zpsut3cdbeu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7883_zpsut3cdbeu.jpg.html)


First job was to fit the window switch surrounds. This was very nerve wracking as I needed to cut away a lot of the leather, but I got there in the end and really pleased with them. I also bonded them in from underneath as well.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7884_zpsxjoacefa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7884_zpsxjoacefa.jpg.html)


Then for the large hole underneath the H-gate – the leather needed to be cut and glued/stapled back underneath. But first I pierced the holes for the Allen bolts and pre-fitted the H-gate.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7885_zpspuwagvsu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7885_zpspuwagvsu.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7886_zpsopvricna.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7886_zpsopvricna.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7887_zpsi2fsrvlp.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7887_zpsi2fsrvlp.jpg.html)


I had asked for the handbrake gaiter not to be fitted, but the trimmer did it anyway. I was a bit concerned that it wouldn’t fit, so I had to try it on the car before bed. It fits!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7888_zps4hkhd1ry.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7888_zps4hkhd1ry.jpg.html)


So below is with the chrome tube on the stick

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7889_zpsgyjcjh7c.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7889_zpsgyjcjh7c.jpg.html)


And below here is without it

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7890_zpslqkjv2hu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7890_zpslqkjv2hu.jpg.html)


So next is to paint the inside of the console a bit in black to hide the wood and then fit up the window switches
Title: Re: Paul's 4thirty Build
Post by: beemaman on June 27, 2015, 07:13:46 AM
Looks great Paul terrific work buddy :)
Title: Re: Paul's 4thirty Build
Post by: Wizard on June 27, 2015, 09:27:46 AM
Looks brilliant and the best part is, you built it yourself.
Title: Re: Paul's 4thirty Build
Post by: Furrari on June 27, 2015, 01:37:20 PM
I can only say "wow"
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 27, 2015, 05:31:07 PM
Car got new rear tyres today. Some nice Pirelli's. So now the car has passed its mot. Hooray.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 28, 2015, 07:59:21 AM
Well it is 7.30am on a Sunday and I have just finished the centre console! Hooray! (Shouts my long suffering wife, Jules!)  ;D All I can say is black was definitely the right colour choice. I love it, especially with the red double stitching.

Anyway, yesterday I added the window switches. I positioned them just right so they weren’t touching the chrome surrounds and then put a dab of stixall to keep them in place. I then screwed in the wooden brackets that are designed to support the switches from underneath to stop them being pushed back into the hole when pressed and painted it all black underneath.


(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5345_zpsd8r0e1o8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5345_zpsd8r0e1o8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5346_zps3ie7twbu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5346_zps3ie7twbu.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5347_zps1l65m4ic.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5347_zps1l65m4ic.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5348_zpstjumagux.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5348_zpstjumagux.jpg.html)


Then it was crunch time – installation. In the end I attached the H-Gate first as it was too awkward to do it with the centre console in place. I used wing nuts so it was possible to tighten up from the top without the need for a spanner underneath. The wings catch on the wooden frame underneath so they don't spin when I tighten the allen bolts. Connected up the window switches and checked they worked.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5371_zpsxmva3yn6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5371_zpsxmva3yn6.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5372_zpsoemtrn4l.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5372_zpsoemtrn4l.jpg.html)


My tube dilemma continues. I can’t use the chromed metal one as it is simply too fat. It would knock on the H-Gate with every gear change and I don’t want that. The painting of the original stick in chrome didn’t really work, so I’ve got a plan C.  This is plastic chrome trim that people use for radiator pipes. As it isn’t a continuous tube the internal diameter can be made smaller by squeezing together. I trimmed a bit of the excess off and then added a couple of O-rings to keep it together and slid over the original stick.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5375_zpsy0vyd9cb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5375_zpsy0vyd9cb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5376_zpsnmt32zqv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5376_zpsnmt32zqv.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5377_zpsufluo9un.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5377_zpsufluo9un.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5378_zpsgph2r49h.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5378_zpsgph2r49h.jpg.html)


I taped it up at the top where the gear knob goes as well. Longer term plan would be to try and find a plastic chromed tube like this that is continuous so if anyone knows of one, please let me know. Or maybe just a different colour one that I can spray. As it is plastic and not metal it won’t chink if it hits the h gate.

Anyway put the knob back on and it is all done! Here are a few pictures. Hope you like it. I’m really pleased how it has all turned out. It’s certainly lost the plastic look.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5379_zpsqjdpnltu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5379_zpsqjdpnltu.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5380_zpsc4s5nxpq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5380_zpsc4s5nxpq.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5381_zpssy7kivss.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5381_zpssy7kivss.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5382_zpsxxdcaqhu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5382_zpsxxdcaqhu.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5385_zpsbilhmeod.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5385_zpsbilhmeod.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5386_zpshsqamb13.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5386_zpshsqamb13.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5387_zpsk10enfws.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5387_zpsk10enfws.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: beemaman on June 28, 2015, 08:04:54 AM
Cracking job Paul looks fantastic :)

I always wanted to do my 430 one but never had time.

Will look even better with dash kit in :)
Title: Re: Paul's 4thirty Build
Post by: Phils99 on June 28, 2015, 08:45:41 AM
brilliant job mate, looks awesome.....need to get round to doing mine!
Title: Re: Paul's 4thirty Build
Post by: ferrari feb 14 on June 28, 2015, 10:53:27 AM
Hey Paul the console looks fab mate  ,as for the gear lever is there any way of removing it and swoping it for a length of 10mm stainless bar , that's what I used on mine ( I no mine is a different set up ) just a thought ,cheers jd
Title: Re: Paul's 4thirty Build
Post by: cheets on June 28, 2015, 12:14:27 PM
Looking really good bud  :)
Title: Re: Paul's 4thirty Build
Post by: MADMAN on June 30, 2015, 09:23:12 PM
Excellent job Paul,
another part of the mr2 gone
MADMAN
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 01, 2015, 10:59:24 AM
Thanks for the great comments guys

I am now working on a secret project to get rid of more of the mr2. 😉😉😉
Title: Re: Paul's 4thirty Build
Post by: Lee22 on July 01, 2015, 11:42:22 PM
Come on Paul, do tell....!

I'm sure whatever you do, it will look amazing, like everything else you have done....

My guess is around the ashtray and radio?

Lee
Title: Re: Paul's 4thirty Build
Post by: V8 KLR on July 02, 2015, 01:03:38 PM
speedo/rev cluster pod surround thing is my guess.....Im going to do something with mine as I hate it.... >:(
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on July 02, 2015, 11:01:34 PM
Car looks fantastic mate.
Like your work on the centre console. Looks great.
Now you cannot put us on the donkey and not let us have a ride!
That's not allowed. You need to give us some clues, at least.  :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 03, 2015, 11:12:29 PM
Ok guys. Here's a BIG clue. I'm not great at keeping secrets especially when I'm excited.  ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 07, 2015, 11:15:14 PM
Well tonight I basically finished my secret dash project. Thanks to all who had a guess. I kept it mostly a secret as wasn't sure how it was going to turn out but I am very pleased now.

I have gone one step further and tried to replicate the ferrari lower dash area but removing the double din radio and ashtray area. I took plenty of photos of how I did it which I will post at a later date but in summary it involved, removing the support legs, making new support brackets that sat further towards the front of the car, new radio, a radio surround made out of wood and covered in same leather as centre console and a floor plate made of wood covered in carpet to hide the wires and gaps in the mr2 carpet.

Big thanks to Wizard and 360mk build (Ranj and Mark) for their help and advice along the way. Here's some pictures. Hope you like it.  ;D
Title: Re: Paul's 4thirty Build
Post by: Wizard on July 07, 2015, 11:28:42 PM
Paul. This look absolutely fantastic. Really pleased it worked out so well.

And yet again, u made it all yourself, from design to execution. Another job made to perfection.
Title: Re: Paul's 4thirty Build
Post by: Lee22 on July 07, 2015, 11:35:24 PM
Superb Paul...... Just brilliant.

Lee
Title: Re: Paul's 4thirty Build
Post by: ferrari feb 14 on July 08, 2015, 08:35:20 AM
Looks fab Paul and defo more like the Oem 430 , great job as always ,jd
Title: Re: Paul's 4thirty Build
Post by: beemaman on July 08, 2015, 10:35:39 AM
Great as always buddy :) really professionally done
Title: Re: Paul's 4thirty Build
Post by: 360MKbuild on July 08, 2015, 01:32:27 PM
Excellent. And it's in there solid so no noises. Looks great. That's phase 1!!!!! :)
Title: Re: Paul's 4thirty Build
Post by: cheets on July 08, 2015, 01:46:56 PM
Look really good Paul and will look amazing with the top dash on :)
Title: Re: Paul's 4thirty Build
Post by: NYAL F430 on July 08, 2015, 02:01:26 PM
Amazing work paul, alot of dedicated time and effort in your build, great work :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 08, 2015, 09:29:22 PM
thanks for all the positive comments guys. they mean a lot!  :);
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 08, 2015, 10:03:45 PM
So here’s how I did the lower dash…

First I removed all the radio and ashtray to expose the metal support bars

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5405_zpswrlwjhtr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5405_zpswrlwjhtr.jpg.html)

The support bars are bolted to the floor by 1 bolt either side, and then at the top, they are bolted directly to the metal cross member that runs under the dash. To get to these nuts it is best to take out the glove box and also the dash surround under the steering wheel to gain better access. Also it is probably best to remove the speedo as well as there is also a box that is mounted with a screw that if you remove it is a lot easier to get to the nut on the driver’s side. There are also some wires that are earthed to these bars that you need to remove to get the bar out. The support bars also have other side parts that the dashboard bolts to as well either side.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5411_zpscgzvzrcl.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5411_zpscgzvzrcl.jpg.html)


So eventually you get them out and they look like this:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5431_zpsckclhjaq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5431_zpsckclhjaq.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5435_zpstvvenacy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5435_zpstvvenacy.jpg.html)


I also noticed that behind the glove back there looks like an area where there should be a bracket, so to aid strength I made one like below:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5438_zpspobh41uw.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5438_zpspobh41uw.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5439_zpsqsy48pmw.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5439_zpsqsy48pmw.jpg.html)


So the plan was to still use the support bars to mount the single din radio directly to, so I took the plunge and after measuring I cut them down. No going back after that!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5436_zps54uzlufb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5436_zps54uzlufb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5437_zpsyhzveeth.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5437_zpsyhzveeth.jpg.html)

So I added the bars back and then started on a mock up for the radio surround out of cardboard.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5440_zps8pyq2qjk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5440_zps8pyq2qjk.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5441_zpsicdbdhqo.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5441_zpsicdbdhqo.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5442_zpsux2zjqhk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5442_zpsux2zjqhk.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 08, 2015, 10:09:43 PM
Then I got the single din radio and decided the best way to mount it would be to bolt directly to the MR2 support bars. On these radios there are a lot of screw bolt holes to do this, so I found one either side that would mean the radio sat the right distance forward, packed it out either side so it sat in the middle and bolted up. I used the square holes that were already in the bars as they are large and have lots of room for adjustment, and just had plenty of washers to bridge the hole.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5446_zpshoqrrq7w.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5446_zpshoqrrq7w.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5447_zpssycpkzmc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5447_zpssycpkzmc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5447_zpssycpkzmc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5447_zpssycpkzmc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5452_zps7ici5kog.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5452_zps7ici5kog.jpg.html)


I then cut the hole out for the radio in my cardboard template and tried it all out

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5457_zpshepq9y65.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5457_zpshepq9y65.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5458_zpswtbdgcz4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5458_zpswtbdgcz4.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5460_zps9g5qofhu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5460_zps9g5qofhu.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5461_zps6o3wu0xp.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5461_zps6o3wu0xp.jpg.html)


I wasn’t happy with the radio height. It still sat too low, so thought about ways to make it higher.
Title: Re: Paul's 4thirty Build
Post by: beemaman on July 08, 2015, 10:14:35 PM
Your the man Paul :) quality work and write up the same quality and detail only too people use :)

Keep up the good work bro
Title: Re: Paul's 4thirty Build
Post by: cheets on July 09, 2015, 12:49:21 PM
Like it Paul wen are you starting on the top of the dash ?
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 09, 2015, 04:40:54 PM
Like it Paul wen are you starting on the top of the dash ?

don't tempt me... I said I'd leave it till after Xmas, but I am not sure I can wait with it sitting there like that! lol
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 09, 2015, 09:44:09 PM
So next was to try and raise the radio up higher. In the end I cut out the square holes in the support legs higher so it would enable the bolts to go higher thus raises the radio up. I also trimmed down some of the lip on the outer edges. This would give me more room for the sides of the radio surround I would make. Finally I cut more of the bottom of the support legs off as this area was not needed and would get in the way of the radio surround.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5474_zpspfrocsd2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5474_zpspfrocsd2.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5475_zps3ykfwpwy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5475_zps3ykfwpwy.jpg.html)


Here you can see how much I managed to raise it up when compared to the original cardboard template

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5477_zpsphe0t4fu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5477_zpsphe0t4fu.jpg.html)


Then I covered the whole template in back tape to get a sense of what it was going to look like

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5478_zpsck81ilbz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5478_zpsck81ilbz.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5479_zpsqpwedjcp.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5479_zpsqpwedjcp.jpg.html)


Next I started to think about the extra brackets. I went a bit crazy at tool station and bought this little lot:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5468_zpskkuxcijj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5468_zpskkuxcijj.jpg.html)


I basically attached a horizontal piece of metal to the bottom of the remaining MR2 support leg that went towards the front of the car and then had an offset l-shaped bracket that went downwards and bolted this underneath a star bolt that attaches to the floor of the car. Pictures say it all really. I made it all with plenty of adjustment so I could get it just right. I was pleased with this as I didn’t need to drill any extra holes in the car body etc.. and it all could be removed should anything go wrong.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5482_zpsykzori0m.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5482_zpsykzori0m.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5483_zpssmgsfufj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5483_zpssmgsfufj.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5486_zpsjajnefbe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5486_zpsjajnefbe.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5487_zpsu0zjj4ov.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5487_zpsu0zjj4ov.jpg.html)


Fitted all the radio back to make sure all was well

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5490_zpsroukuy2i.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5490_zpsroukuy2i.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 09, 2015, 09:52:10 PM
Next I started to trim away some of the carpet and sort out the wiring for the radio and tidy it all up

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5491_zpsq5uaoeho.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5491_zpsq5uaoeho.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5492_zpsy5iigpoi.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5492_zpsy5iigpoi.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5493_zpsmex3b77x.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5493_zpsmex3b77x.jpg.html)


Then I made the radio surround out of 3mm MDF

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5504_zpswa1ray1l.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5504_zpswa1ray1l.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5503_zpspr266ksj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5503_zpspr266ksj.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5499_zps0ttthrfs.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5499_zps0ttthrfs.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5500_zpssoiqxsdq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5500_zpssoiqxsdq.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5502_zpsj6soxhi0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5502_zpsj6soxhi0.jpg.html)


In the end I made the hole for the radio bigger to allow for the thickness of the leather and also rounded off the bottom so the leather could have something to curve around. I also added some mending plates at the rear. These would bolt to the horizontal parts of my new support legs to keep the radio surround all in place.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5507_zps3xbnwbfd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5507_zps3xbnwbfd.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5506_zpswjq80s3y.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5506_zpswjq80s3y.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 09, 2015, 09:57:16 PM
While the surround was at the trimmers I set about making the cover to hide the gaps in the carpets etc…

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5518_zpsapjn6jdq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5518_zpsapjn6jdq.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5517_zpsy6b5fclw.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5517_zpsy6b5fclw.jpg.html)


I decided to utilise the bolt holes where the mr2 supports legs originally bolted to in order to secure this cover when it was finally in place. I would just get some black domed allen bolts so they wouldn’t show.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5515_zpsqcecwlut.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5515_zpsqcecwlut.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5513_zpse73p2bjn.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5513_zpse73p2bjn.jpg.html)


The trimmer did the surround in a couple of hours so Dad kindly picked it up for me the next day. I couldn’t wait to try it out as I was worried the thickness of the foam and leather would cause issues, but luckily it fitted like a glove!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5527_zpsq2xqc6lg.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5527_zpsq2xqc6lg.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5526_zpsqpnd3ncn.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5526_zpsqpnd3ncn.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 09, 2015, 10:02:07 PM
Then it was just a case of covering the floor surround in black carpet

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5533_zpswpych2md.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5533_zpswpych2md.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5534_zpsjjtayzz4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5534_zpsjjtayzz4.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5537_zpsqs8yps7z.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5537_zpsqs8yps7z.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5538_zpsaofbsrcr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5538_zpsaofbsrcr.jpg.html)

…and then trailed fitted it. Simples!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5542_zpsle7k2gzn.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5542_zpsle7k2gzn.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5543_zps2w7ixol7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5543_zps2w7ixol7.jpg.html)


All that is left to do is bolt the surround in permanently and then bolt the floor cover when the black bolts arrive and we are done!

Title: Re: Paul's 4thirty Build
Post by: cheets on July 10, 2015, 12:29:48 PM
its really looking good bud :) 
Title: Re: Paul's 4thirty Build
Post by: Lord Beany on July 11, 2015, 08:21:26 AM
Great job Paul. I think many will want to copy this mod.😉

Beany😁
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 12, 2015, 07:18:05 AM
Lower dash project is now competed. I bolted the radio surround in place so that is now solid and then bolted the floor cover using these black Allen bolts so you can't really see them

(http://i1315.photobucket.com/albums/t597/pjlucas1/20150711_073219_resized_zpssvxsaf4a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20150711_073219_resized_zpssvxsaf4a.jpg.html)



Next, in preparation of doing the top dash I have been thinking about where to put the hazard switch. Mark360 kindly gave me a spare hazard switch he had to play around with.  In the end I have gone down one the discreet route. I have placed it on the lower driver’s side dash surround.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20150710_220040_resized_zpsit9va0lq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20150710_220040_resized_zpsit9va0lq.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20150710_220056_resized_zpsjotopnir.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20150710_220056_resized_zpsjotopnir.jpg.html)

 I removed the surround and drilled a 25mm hole put in place. To secure the switch I bonded 2 L-shaped brackets to the sides and then drilled small holes in the surround so it could be bolted from the front.   The Allen bolts don't show really and if they get in my nerves I can always change to black ones. The switch is very accessible so should be ok for the mot. In fact it is closer to your hand than the original.

(http://i1315.photobucket.com/albums/t597/pjlucas1/20150711_062657_resized_zps02loddsk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20150711_062657_resized_zps02loddsk.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20150711_062709_resized_zpsfmmlc9qu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20150711_062709_resized_zpsfmmlc9qu.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20150711_070506_resized_zps7yyn7zfr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20150711_070506_resized_zps7yyn7zfr.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20150711_070519_resized_zpszunes8pk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20150711_070519_resized_zpszunes8pk.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20150711_070748_resized_zpsnqylniws.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20150711_070748_resized_zpsnqylniws.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20150711_072124_resized_zpsy13arn5k.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20150711_072124_resized_zpsy13arn5k.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20150711_072131_resized_zps9shjcynf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20150711_072131_resized_zps9shjcynf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20150711_073051_resized_zpsrbjq6cbp.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20150711_073051_resized_zpsrbjq6cbp.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20150711_073231_resized_zpsg9c6fgob.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20150711_073231_resized_zpsg9c6fgob.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/20150711_073324_resized_zpslzeyjjkz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/20150711_073324_resized_zpslzeyjjkz.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 12, 2015, 08:05:10 AM
Great job Paul. I think many will want to copy this mod.😉

Beany😁

Be my guest Beany - I'm sure I still owe you a few ideas!  ;)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 21, 2015, 07:23:36 PM
Been doing a bit of dash work. Yes, you guessed it. There was no way I was gonna wait till next year to do it. Taking a slightly different route and doing away with the square frame that goes around the bottom of the hvac face plate. Also going to fit the scudo bezels aswell.

Title: Re: Paul's 4thirty Build
Post by: rudycob1 on July 21, 2015, 08:19:30 PM
Looking great as always mate.  :)
Title: Re: Paul's 4thirty Build
Post by: Lee22 on July 21, 2015, 10:41:30 PM
Nice one Paul...

Will look amazing mate
Title: Re: Paul's 4thirty Build
Post by: cheets on July 22, 2015, 03:00:10 AM
Looking good  :) Paul i am so jealous you doing your bits and i can not do anything on mine just 38 days to go :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 23, 2015, 10:25:55 PM
Next job was to remove air vents. These are a pain to get out without breaking but as they aren't going to used again it doesn't really matter. I found best way is to stick a small hacksaw blade down the sides and saw off the little pegs that the slatted vents pivot on. So here is all four removed. On the outside vents I also removed the plates that the slide wheels open and close as these won't be needed.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 23, 2015, 10:54:43 PM
Then it was tackling the  hazard switch. As you know I had another switch and already mounted it (cheers again Mark) and I definitely recommend this route. This is because trying to get the original out is a right pain. You'd need to cut away the front panel and pull the switch forward. I didn't want to do that really but I still had to get to the connector behind the original switch. Best way is to remove the hvac unit and go in from underneath. Switch connector came away very easily.

Then is was the tricky task of extending the wires. I got there in the end and after a test I wrapped all wires up in tape and then zip tied inside the dash and put it all back together.

Next I'll be doing more work on the centre vent surround but that's for the weekend.
Title: Re: Paul's 4thirty Build
Post by: Furrari on July 25, 2015, 08:17:02 AM
Have you thought about doing something simpler in your spare time.  Brain surgery perhapse.?
Your level of work and detail are an inspiration to us all.  Brilliant.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 25, 2015, 11:21:38 PM
Have you thought about doing something simpler in your spare time.  Brain surgery perhapse.?
Your level of work and detail are an inspiration to us all.  Brilliant.

thanks for the kind words Mick/Guys. I just love doing these things and telling you all about it. Much better than watching gardener's world! lol   ;D

Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 25, 2015, 11:23:47 PM
So a bit more dash brain surgery today…..

I have decided to remove the passenger airbag. I did this for the following reasons:

1)   I believe it doesn’t work anyway as I have removed the drivers one for the steering wheel conversion
2)   I am wary still having it installed with an extra cover on top (the 430 dash)  in case it ever somehow when off
3)   It’s heavy and I think is the cause of an annoying dash rattle I have always had one the car.

So it is now out. It comes out quite easily. Remove the glove box, and then there is a bolt at the bottom of the airbag in the middle and then a nut at each side of it near the top of the dash. You’ll also need to remove the bonnet release pull handle (2 bolts) as this is bolted to the bottom of the air bag unit. Once these are undone it will pop out through the top of the dash along with the dashboard cover part as it is all connected together.

Once out and one the bench, I removed the actual dash cover from the airbag as I wanted the cover back on the dash and when fitting the 430 dash top I will bond this airbag cover permanently in. The airbag cover is secured to the airbag unit via security screws among other things, so the best way is to cut the plastic around it and remove it this way. All you need is some tin snips and snip away at the plastic.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5654_zpsy4w5w1ah.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5654_zpsy4w5w1ah.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5655_zps4zjtldy9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5655_zps4zjtldy9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5656_zps9d4u7brq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5656_zps9d4u7brq.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5657_zps1rymrtxx.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5657_zps1rymrtxx.jpg.html)


This is the naked airbag – anyone recommend how I dispose of this?

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5658_zpswe3qvfhp.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5658_zpswe3qvfhp.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 25, 2015, 11:27:50 PM
Other bits done today….

Because I have decided to do away with the lower surround part of the centre air vent surround and I have cut it away, this left some gaps. I have filled these in now and sanded down

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5659_zpsbzx0xklq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5659_zpsbzx0xklq.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5660_zps5s25xigt.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5660_zps5s25xigt.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5661_zpsotzmeq1i.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5661_zpsotzmeq1i.jpg.html)


Cut out the holes in the side vents on the dash top

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5662_zpso2djehnj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5662_zpso2djehnj.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5663_zps2me0zlzm.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5663_zps2me0zlzm.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 25, 2015, 11:53:27 PM
Next I had to think about relocating the bonnet pull now the airbag was gone. I wanted to keep it in a similar place as before. I thought about mounting it outside the glove box but there wasn’t really any suitable place to mount it.  So  the end I did the following:  I took a mending plate and enlarged the holes. I bolted the bonnet pull to the end of the mending plate using nuts to space it out slightly as the bonnet pull is mounted at an angle.

I then bolted the mending plate to the place where the airbag lower bolt was originally to come up with the below. It sits a little higher inside the glove box than before but it works perfectly fine and the mending plate is thick enough and secure enough not to bend when you pull the handle.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5687_zpsxthiffoy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5687_zpsxthiffoy.jpg.html)

The fire extinguisher is just there because it sits in my glove box and the glove box was closed. If you try to mount the handle any lower down you’re going to run into problems as it means you won’t be able to remove the glove box if you need to as the bonnet pull handle will get in the way of the back of the glove box
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 25, 2015, 11:59:19 PM
The final thing today was thinking about how to secure the centre air vent surround well enough but to still make it removable. I never like the idea of mounting things permanently in case you need to remove them to get to other things. I can understand bonding the top dash cover permanently as this doesn’t in theory get in the way of anything, but the centre vent surround, if bonded permanently would mean you could never remove the HVAC panel again.    
   
So…my plan to secure the centre vent surround is via using dum dum at the top of it and then some sort of bracket system lower down. The surround is very light but when you have 3 vents in there it gets quite heavy. So extra support here will definitely help. I put my thinking cap on and came up with the following:

I had some L-shaped brackets and screwed one to each end of the square holes left behind by the MR2 air vent removal. I then plan to have the same brackets on the vent surround and when all bonded in place, the surround can be bolted to the main dash through the 3 circles and made more secure. The bolts don’t need to be massive but this make the whole thing removal if needed.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5688_zpsilrblzub.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5688_zpsilrblzub.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5689_zpsdplsapl3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5689_zpsdplsapl3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5690_zpsx1kkxqbo.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5690_zpsx1kkxqbo.jpg.html)


I have now bonded the pieces and will leave to dry overnight

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5691_zpsbucvuaiv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5691_zpsbucvuaiv.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5692_zpsvlhkyddm.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5692_zpsvlhkyddm.jpg.html)


Also with a vent in place there is plenty of clearance

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5694_zpsbdudpree.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5694_zpsbdudpree.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 26, 2015, 12:05:02 AM
You can also see in the below picture I have extended the dash top cover slightly. On the left I added a very small lip so the vent surround is closer to the dash as there was a gap there. On the right I've extended this curve downwards to be in line with the other side and remove a gap I had with this and the vent surround.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5689-2_zpsa17blwmz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5689-2_zpsa17blwmz.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: cheets on July 26, 2015, 03:05:42 AM
Nice wok Paul i was going to fasen the top of the vent done under the F430 badge but looking good
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 26, 2015, 12:37:34 PM
***Need some help guys***

The last thing I need to work on is the Scudo bezels I have got. I have back trimmed them all fine but how the whole thing fits together I am a bit stuck on.  :'(

Referring to the below photo

A – scudo bezel
B – air vent
C – part that air vent B sits in side
D – outer ring that screws onto part C
E – vent surround – basically when all fitted D butts up against E

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5707_zpsae3iqnka.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5707_zpsae3iqnka.jpg.html)

Am I correct in saying that the when fitted, the bezel A should butt up against E? If so does that mean D is no longer used, and also does C need grinding back? Also part C can come apart if required as it has 2 tabs but these are currently glued in place so the piece doesn't come apart

Also on my bezels, 4 of them on the inside have fibre glass resin filled in (#2 below) where as only 1 is like #1 below. Is this also going to cause problems?

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5708_zpsu3gagntf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5708_zpsu3gagntf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5709_zpshq6aevpl.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5709_zpshq6aevpl.jpg.html)

Thanks all guys
Title: Re: Paul's 4thirty Build
Post by: beemaman on July 26, 2015, 12:49:39 PM
Paul I used a block and 80 grit flat across the face of the fiberglass vent surround  then the scudo bezel goes onto that.if you block it as flat as possible you can place the scudo bezel on top to see how flat youve got it.thats how I did it and it was fine unless someone knows another way.

I'm sure I didn't use the part d just bonded in the vents from behind.but I did need to remove some of the dash were vents fitted with airsaw as vents sit further back when using scudo bezels .
Title: Re: Paul's 4thirty Build
Post by: cheets on July 26, 2015, 01:33:06 PM
Hi Paul i did the same as beemaman i have not used D C i donned in from the back of E and A i have to bond on to the front of E

wen i bonded C in i had the B in so i cud set the depth with holding A on

Pic 1 is the C bonded in
Title: Re: Paul's 4thirty Build
Post by: cheets on July 26, 2015, 01:38:18 PM
next the front with C in the next 2 all assembled with a just sat on i did have to cut a lot of the old vents out of the dash as well sorry don't have any pice on me if you need then can get dad to take some and for you

Hope this helps Mark
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 26, 2015, 05:58:19 PM
thanks for coming back so quickly guys. Yes I see how it all works now. Lots of extra work  :'(

Also i means the vents are fixed permanently in the surrounds which is something i didn't want to do. so i have come up with another idea. watch this space.  ;)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on July 26, 2015, 06:12:12 PM
So in order to make sure all was well before i bite the bullet and get it all trimmed, I simulated the fitting of the top cover more permanently. First was to add some dum dum in various places and then press in place. Next I think I will pack out the centre section with wood when I come to bond permanently. Then it was time to test out my centre vent bracket idea. PLeased to report it works really well and the surround is really solid in place.  ;D. It is secured at the top with blobs of dum dum as well. Went fitting for real i'll ensure that the washers and nuts etc.. used in the brackets are black as you can see the silver though the vents when open.

Title: Re: Paul's 4thirty Build
Post by: rudycob1 on July 26, 2015, 08:16:20 PM
Hi,
I fitted mine the same as you have already been advised by Beemaman etc.
Like the idea of the brackets and I will be looking at this as I might copy this idea.
Great work, as always.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 01, 2015, 10:20:36 PM
thanks for all the comments and help guys. I've decided to leave the scudo bezels for now and carry on as planned. I dropped the dash cover off at the trimmers today. Not sure when it will be done but it wont be too long. The whole dash will be done in time for kit car live in November. I am getting the vent surround all painted by Beems in lovely shiny gloss black soon  ;D ;D ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 02, 2015, 06:17:45 AM
As I have 4 spare mini vents that I got 2nd hand off eBay ages ago, I thought I’d use them to experiment with different styles in terms of ring colour etc… spraying various parts silver to see what they would look like fitted. I tried the outer ring, inner ring and then both the same. I think the best one is having the inner ring silver on its own (2nd photo down), which is the same thing Phil did on his.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5715_zpsxbre2vxh.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5715_zpsxbre2vxh.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5716_zpsiiy6ntnb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5716_zpsiiy6ntnb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5717_zpsnfdrb4x3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5717_zpsnfdrb4x3.jpg.html)


Next, to fit the vents in the centre vent surround, for the vent in the middle you need to trim away the edges of the outer ring in order for the 3 to sit nicely in a line. This is a just a trial and error exercise. See below – just used the power file to gradually get it right

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8398_zpsx84jpos6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8398_zpsx84jpos6.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8399_zpsazcozsjd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8399_zpsazcozsjd.jpg.html)


So here are all 3 in a line

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8400_zpsknt6pg3k.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8400_zpsknt6pg3k.jpg.html)


Dash finally all mocked up ready for the trimmers

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8402_zpspppnoxyn.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8402_zpspppnoxyn.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 02, 2015, 06:32:01 AM
I had always planned to fit the little horses in the centre of the vents, like many of the guys had done but one night I had the idea to perhaps change the actual knob on the vent. The real car has much smaller, rounded knobs compared to the mini flower-styled knobs. Again it was back to the old vents for testing! 

So I ground away the flower-style knob to leave just a stump and then fixed a new style knob I had bought from Maplins

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8451_zpsljteevyi.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8451_zpsljteevyi.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8448_zps9mfrlr73.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8448_zps9mfrlr73.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8453_zpsce3avuf3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8453_zpsce3avuf3.jpg.html)


Different, and then I sprayed it silver to see the difference

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8457_zpsdw0iar5n.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8457_zpsdw0iar5n.jpg.html)


I was not sure about this one  - I think the knob should be more round shaped as opposed to the flower shaped, so had a look on eBay and found some more round styled aluminium knobs

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8521_zpsrlthf0pr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8521_zpsrlthf0pr.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8524_zpsczwjhfzs.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8524_zpsczwjhfzs.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8523_zps9ebjlgxw.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8523_zps9ebjlgxw.jpg.html)


The knobs needed trimming down as they protruded too far initially but I think I am happy with these now

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5773_zpstsrvuokb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5773_zpstsrvuokb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5775_zpszta1p2cf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5775_zpszta1p2cf.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: ferrari feb 14 on August 02, 2015, 12:13:46 PM
Looking good Paul as always mate ,nice touch with the knobs ,jd
Title: Re: Paul's 4thirty Build
Post by: cheets on August 03, 2015, 04:30:38 AM
Nice work bud had not noticed the nobs was different will have to have a look at them wen i get home know another job hehehe

Mark
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 08, 2015, 07:51:54 PM
Time for an update peeps on my knob project. LOL

So I’ve finally bitten the bullet and gone for the new knob look. First thing to do was trim down then knobs to about half the size. This was a delicate operation using the trusty power file (DNA should really include this as part of the kit as it is sooooo useful) so below is 5 trimmed ones vs the original size. For anyone who’s thinking of doing this, here’s the eBay link to the knobs.

http://www.ebay.co.uk/itm/221837903365?_trksid=p2057872.m2749.l2649&var=520720836594&ssPageName=STRK%3AMEBIDX%3AIT

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5786_zpshdlvnb44.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5786_zpshdlvnb44.jpg.html)


Then it was time to remove the mini ‘flower’. First I got some u-channel trim and added to the vent to protect it in case the power file went astray and secured with tape

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5793_zps3tgdgqto.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5793_zps3tgdgqto.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5796_zpskf5z3pq9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5796_zpskf5z3pq9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5797_zpseuv866fx.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5797_zpseuv866fx.jpg.html)


Then basically use the power file to gradually grind away the flower petals.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5799_zpssjoegyb0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5799_zpssjoegyb0.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5800_zpsokhhlbzl.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5800_zpsokhhlbzl.jpg.html)


Eventually as the petal disappears you’ll hit metal. This is a spring. Just grind away so you can see a whole metal circle

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5801_zpsk2915sam.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5801_zpsk2915sam.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5802_zps3xc7d40q.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5802_zps3xc7d40q.jpg.html)


Then you can remove the spring and you are left with a stump. Tidy up the stump and then fix in the knob. The knob is a nice tight fit – I probably won’t even need to bond them

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5804_zpso7nty0k5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5804_zpso7nty0k5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5806_zpsrgfngyha.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5806_zpsrgfngyha.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5807_zpsl4ueguik.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5807_zpsl4ueguik.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5808_zpsxnqvhqfc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5808_zpsxnqvhqfc.jpg.html)


As you get more confident you can get away with just sinking the power file into the middle of the flower. (I.e. no need to grind away the petals) to reveal the spring and the flower just come away. By the 4th vent I managed to do it in less than 2 mins from start to finish.

All five done

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5813_zps60npdndq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5813_zps60npdndq.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: 360MKbuild on August 08, 2015, 10:07:52 PM
They look great, big improvement. The dash is going to look really good.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 09, 2015, 07:02:12 AM
The vent surrounds have also been sent to Beems for painting  - they are all going to be gloss black and I am filling in the 430 badge recess as well as I prefer the flush look.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5814_zpskrhgxpuc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5814_zpskrhgxpuc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5815_zpshkupivab.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5815_zpshkupivab.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5816_zpsvk07fad3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5816_zpsvk07fad3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5817_zps8o16q2n6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5817_zps8o16q2n6.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5818_zpsitueta2f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5818_zpsitueta2f.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 11, 2015, 09:30:47 AM
Quick vent update people. They are basically all painted and now fitted up ready for the dash.

I decided to paint the parts silver where the vent ball sits inside. This involved a lot of masking up and I also removed the felt from the inside. Once painted, I then added some new felt. Originally there are 2 strips of felt, but I added back one bigger one to line the inside of the ring. This does make the vents stiffer to move around but that really doesn’t bother me. I’d rather they were more secure in place and facing forwards. My car doesn’t have air con anyway and there is plenty of heat inside the cabin from the engine.

Here are some pictures

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5819_zpsikenk9ml.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5819_zpsikenk9ml.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5843_zpsdtciacpk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5843_zpsdtciacpk.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5844_zpstzgbu0wb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5844_zpstzgbu0wb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5846_zpss5tn4mko.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5846_zpss5tn4mko.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8666_zpso8otqvlc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8666_zpso8otqvlc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8667_zpswp0kauow.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8667_zpswp0kauow.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 11, 2015, 09:31:21 AM
also spoke to the trimmer yesterday - picking up the dash on saturday!  ;D
Title: Re: Paul's 4thirty Build
Post by: Furrari on August 11, 2015, 06:20:13 PM
Wow.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 11, 2015, 06:59:22 PM
I was clearing out the shed yesterday and came across the old Krook-Lok that I had bought ages ago. I had added the Ferrari sticker then but at the time I couldn’t get the lock to actually work. I think it was a combination of the normal MR2 gear shift and gaiter set up. But now I have a new gearbox and centre console I thought I’d give it a go again. I was well happy as it worked properly as it should. And to think I nearly dumped it!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5858_zpswovct6ki.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5858_zpswovct6ki.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5859_zpsmheo0dde.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5859_zpsmheo0dde.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5860_zpslocieobg.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5860_zpslocieobg.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 11, 2015, 07:23:45 PM
Wow.

thanks Mick - got another trick up my sleeve. Stay tuned
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 11, 2015, 08:10:58 PM
So onto the next project…….

My trimmer suggested whether, as there would be some spare leather, I wanted to cover the glove box. So this got me thinking about the whole thing, especially the handle. I thought about getting a trim surround for the handle, but you know me, I tend to over analyse things and do things differently. I spoke to MK360 and he told me he had thought about trying to move the handle to the right (this was before he did the whole 360 dash conversion) to make it more factory looking. Mmmmm I thought - I had a look at the real 430 and there is no handle there, but not wanting to have too much of a challenge I thought about other options. How about changing the handle to something a bit more easy-on-the eye and moving it so it is no so much in your face?

I took my glove box out, and looked at how it all worked. I then looked at eBay and various glove boxes (sad, I know!) What I wanted was a handle that was a complete unit that could be removed and mounted into a flat surface. I managed to find this - a Jaguar S Type glove box. Looks nice and the handle is a separate removable unit.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8654_zpsgxkm1dgq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8654_zpsgxkm1dgq.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8655_zps95gbwvcx.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8655_zps95gbwvcx.jpg.html)


So the plan is to install this Jag handle lower down in the centre of the MR2 glovebox, where it is more out of sight - on the slope part of the glove box. I would then remove the MR2 handle and the internals and fill in the hole from the front. It would then all be covered in Napa leather with red stitching.  At certain angles you’ll still be able to see it, but at least it isn’t on the vertical part of the glove box and it is a much better looking handle anyway. The lock wouldn’t work, but that doesn’t bother me. I would need to extend down from the inside the metal that the latch catches onto but that should be easily do able. It would need a new thing to catch onto that is slightly off centre and if it all goes horribly wrong I just get another MR2 glove box. But it won’t! (Fingers crossed)

 So I have bought the Jag glove box and should be here in a few days. Meanwhile I printed off the handle and mocked it all up to see what it would look like. I covered up the MR2 handle with tape and then blu-tacked the Jag handle picture.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8690_zpsrtu6ucw8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8690_zpsrtu6ucw8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8691_zpsxhfvb3nr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8691_zpsxhfvb3nr.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8692_zps7es8mtmv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8692_zps7es8mtmv.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8694_zps8n6n3ebc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8694_zps8n6n3ebc.jpg.html)


Where is it? LOL. I’m pleased with it so far. I toyed with it on the left and right hand sides but it doesn’t look as good, plus would be more mechanically challenging to make work.

 (http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5897_zpsxxbbvadd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5897_zpsxxbbvadd.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5898_zpszgoj10c9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5898_zpszgoj10c9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5901_zpsupzhpd4i.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5901_zpsupzhpd4i.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5902_zpsxliy6n3a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5902_zpsxliy6n3a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5903_zpsxmnqidew.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5903_zpsxmnqidew.jpg.html)


I think how low it is mounted on the slope will be determined by the flat slope part. What do we think? Wish me luck guys!!!!  ;)
Title: Re: Paul's 4thirty Build
Post by: 360MKbuild on August 11, 2015, 08:21:25 PM
Looking good. With all these changes it completely removes the mr2 look. Spare glove box here, but you won't need it ;) looking forward to seeing the dash all done.
Title: Re: Paul's 4thirty Build
Post by: cheets on August 11, 2015, 11:05:41 PM
I really do like the look bud go me thinking a gene about what i am going to do its just done to time know with me but nice work :)


Mark
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 11, 2015, 11:10:56 PM
You can always tinker with it after the car is on the road Mark. Just look at me! LOL  ;D
Title: Re: Paul's 4thirty Build
Post by: cheets on August 12, 2015, 12:57:50 PM
yes i know bud and i am shore i will :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 13, 2015, 09:52:29 PM
vent picture update from Beems - with Cheet's green 430 I am going something different on my vents! LOL

Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 13, 2015, 10:20:10 PM
So while I wait for my Jaguar S type glove box handle to arrive (I had a look at one in the zoo car park today and looks like it will be just fine) I start thinking about what else I could tinker with. As my vents and HVAC cover are going to be gloss black, I next thought about the speedo surround. It would make sense that this was also gloss black to match, but what about making it open faced like the real 430? I know Madman and Rudy have done this, but I don’t think there have ever been any notes on this modification. So in speaking with 360MK again (thanks Mark btw) who has a spare speedo surround for me in case it all goes wrong I thought I’d give it a go.

TBH I had thought about this before, but thought it a lot of work, and I did quite like my silver rings on the MR2 surround. But as I’m on my holiday I thought I‘d give it a try. So below is what I currently have:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5919_zpsxjpfv6cv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5919_zpsxjpfv6cv.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5920_zpscgwqv4v3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5920_zpscgwqv4v3.jpg.html)

So I started to take the speedo apart. Remove the clear plastic part and then the black part that the clear part sits in

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5922_zpsnuqog78f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5922_zpsnuqog78f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5923_zpsc6p7yjsy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5923_zpsc6p7yjsy.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5924_zpsjtwjugqt.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5924_zpsjtwjugqt.jpg.html)


And this is what is left

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5926_zpssbphpk97.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5926_zpssbphpk97.jpg.html)

So then I start to chop up the surround. You need to remove all traces of the centre hole curved parts, especially at the top as it has a lip as well.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5929_zpsiylr7okm.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5929_zpsiylr7okm.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5931_zpsj7syjim5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5931_zpsj7syjim5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5932_zpsvhjrkh58.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5932_zpsvhjrkh58.jpg.html)


After 10 mins of sawing and power filing you are left with this:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5933_zpsjvdopx77.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5933_zpsjvdopx77.jpg.html)


Back on the car you have this:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5934_zpsvdgpmagg.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5934_zpsvdgpmagg.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5935_zpsitg7sze1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5935_zpsitg7sze1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5936_zpsztntgrrl.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5936_zpsztntgrrl.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 13, 2015, 10:39:27 PM
So with all my mods I try to keep certain things as standard (and cheap) as possible. I know the real 430 has more dials but I didn’t want to add any more and need a new speedo face etc.. I don’t even want to have to take the dial backs off as all the needles work perfectly now. But in order to hide all the white you can see I need to make a surround that hides it all. I didn’t want to go down the route of the surround covering the speedo face. I plan to make a template that slides just underneath the speedo face all the way around but keep it black so it all blends in. I also have to think about the clear plastic that protects the dials. My planned is to mount to the inside of the modified surround, clear Perspex. Here I need to think about the angle of how the Perspex butts up against the rear of the surround so it is all flush and slopes downwards towards the front of the car.

So for the base of the speedo surround, I trimmed it away further so it slopes downwards slighty. Quite a lot is cut away. I then added a piece of cardboard and taped in place to see how it would look. Plan would be to bond in black plastic and then fill in.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5937_zpsteinyalm.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5937_zpsteinyalm.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5942_zpshddcwdlr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5942_zpshddcwdlr.jpg.html)


Next the top of the surround needs work. I wanted to create a lip like at the bottom to create depth and to have something for the Perspex to butt against. So I took a strip of black plastic probably similar size to that of a 30cm ruler. And then I forced and bonded it in at each side. By using reasonably thick plastic it naturally bends in a curve and creates a nice shape. The gap at the front of the surround would then be filled in and smoothed to the shape you want.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5974_zpskpumekjn.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5974_zpskpumekjn.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5975_zpslqtrorae.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5975_zpslqtrorae.jpg.html)


So I bunged loads of flexible filler to bridge the gap

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5978_zpshoxi6kqo.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5978_zpshoxi6kqo.jpg.html)


I also bonded in a black piece of plastic for the bottom part and left it over night

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5979_zpse9edzwtf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5979_zpse9edzwtf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5980_zpsm8o7b9fy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5980_zpsm8o7b9fy.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5981_zps9z1vvqvj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5981_zps9z1vvqvj.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5982_zpsmqswkpdk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5982_zpsmqswkpdk.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5983_zpskpo04wdb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5983_zpskpo04wdb.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 13, 2015, 10:56:44 PM
So onto the face surround:  After studying the speedo in place on the car, I took the below part and drew around on cardboard.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5984_zpsws6ucvtg.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5984_zpsws6ucvtg.jpg.html)


I then took my old MR2 dials and drew around these inside the above outline. These are my guidelines and I would cut out a hole slightly smaller than the MR2 dial size in order for it to slide underneath them

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5985_zps6u5r7ybp.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5985_zps6u5r7ybp.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5986_zpsksfa6vlr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5986_zpsksfa6vlr.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5987_zps1xxkn3vv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5987_zps1xxkn3vv.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5988_zpscd2a9com.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5988_zpscd2a9com.jpg.html)


So then placed on the car on top of the speedo to look at the fit

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5989_zps25wao3ft.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5989_zps25wao3ft.jpg.html)


I then removed the whole speedo and fitted the cardboard template under the dials backs and then fitted back to the car.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5990_zps6hcu4mcx.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5990_zps6hcu4mcx.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5992_zpsvwlogxds.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5992_zpsvwlogxds.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5994_zpsooxtmxdu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5994_zpsooxtmxdu.jpg.html)


Next, the fixing points that secure the whole unit into the dash potentially shows so I masked most of the speedo unit off and sprayed these bits black

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_5996_zpsqhs8bmfn.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_5996_zpsqhs8bmfn.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6006_zpsnpd2yi2w.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6006_zpsnpd2yi2w.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6008_zpszxa6gdjh.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6008_zpszxa6gdjh.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: beemaman on August 13, 2015, 11:06:10 PM
Hi Paul

Looking great mate love the pink dash parts :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 13, 2015, 11:25:14 PM
So final update tonight: I started to file back the filler on the surround – still got a lot to work on this but the plan is to get it as best I can and then send up to Beems to finish off and paint gloss black once I have mocked everything up.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6001_zpsrmaehi7s.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6001_zpsrmaehi7s.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6002_zpsqxl4lmdg.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6002_zpsqxl4lmdg.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6003_zpszacjnsns.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6003_zpszacjnsns.jpg.html)


So to make the real face surround I have toyed with many ideas. Thin plastic and then covered in CF wrap, or thick cardboard covered in CF wrap. None of which I had to hand. What I did have was some 2 mm thick black plastic that has a grainy effect to it, so I thought I’d give it a go with this for now.

I transferred the pattern to it and cut out. After much shaping and filing later I had this:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6005_zpsflpn1xqz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6005_zpsflpn1xqz.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6017_zps2erebysm.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6017_zps2erebysm.jpg.html)

I then fitted it to the speedo unit and then fitted to the car. I was initially not happy. You could really see the speedo dials on top on the face surround. It really stood out. But then I fitted back the cover and this combined with the shadow it casts, you really cannot see where the dial backs end and the face surround starts. the camera flash doesn't help but I am happy with it. IF I had gone the CF wrap route it would stand out further so glad I am using this material. Once happy with the shape I will spray the face surround, satin black which should help with the blending in further

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6010_zpsibnx80kq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6010_zpsibnx80kq.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6014_zpsblfg2esj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6014_zpsblfg2esj.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6015_zpsuyborjgl.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6015_zpsuyborjgl.jpg.html)

Phew – time for bed!!
Title: Re: Paul's 4thirty Build
Post by: cheets on August 14, 2015, 02:30:00 AM
Looking good bud got me thinking about mine :)

Mark
Title: Re: Paul's 4thirty Build
Post by: V8 KLR on August 14, 2015, 01:55:22 PM
yeah I like that idea, as you know Paul I hate that darn pod thing   >:( so weather looks rubbish... gonna chop mine up at the weekend..... ;D
Title: Re: Paul's 4thirty Build
Post by: Phils99 on August 14, 2015, 03:38:59 PM
Brilliant as always mate...sorry I didnt reply to your last message to me....been mega busy with work and moving house!!
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 15, 2015, 06:55:49 AM
So for the face plate surround I decided to give it a coat of paint - so I primed and painted gloss black.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6026_zpsrjhjh8ya.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6026_zpsrjhjh8ya.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6051_zps0nmdwky5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6051_zps0nmdwky5.jpg.html)


I also tested to ensure all lights behind the dials lit ip and weren’t blocked too much by the surround

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6050_zpsinewl3fy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6050_zpsinewl3fy.jpg.html)


I also made a template for the Perspex that I will fit at the end, and also worked out where the speedo reset knob would poke through. I did this by putting some blu tack on the end of it and then a dab of red paint and with the Perspex template in situ it marked the back of it so I was then able to create a hole.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6018_zpsg6nkxxnc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6018_zpsg6nkxxnc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6021_zpserynhqle.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6021_zpserynhqle.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6038_zpsbx2t9twv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6038_zpsbx2t9twv.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6039_zpswvg1ipbl.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6039_zpswvg1ipbl.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6040_zpsdqk1vqzo.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6040_zpsdqk1vqzo.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 15, 2015, 07:02:20 AM
At the top of the surround I also packed out the corners as well and filled in. This means that the Perspex can lie as flat possible. I plan to use 1mm Perspex which is the same as what is already on the MR2. I had some 2mm delivered but this is too thick I think.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6019_zpso5bip8yy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6019_zpso5bip8yy.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6020_zpsqkngcfbc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6020_zpsqkngcfbc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6022_zpsxa63vfwy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6022_zpsxa63vfwy.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6043_zpsk4hall5k.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6043_zpsk4hall5k.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6044_zpsdmcxtv2t.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6044_zpsdmcxtv2t.jpg.html)


I also rubbed down and shaped the lower part

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6045_zpsjvxdkqs3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6045_zpsjvxdkqs3.jpg.html)


Mark’s spare surround also arrived yesterday (Thanks again matey) and here are the 2 side by side showing the differences.

 (http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6047_zpsvvedynrq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6047_zpsvvedynrq.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6048_zpsxm3uvojw.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6048_zpsxm3uvojw.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 15, 2015, 07:10:25 AM
So we are getting close now for the final fitment. I have also been toying with the idea of a RACE sticker as my dials don’t have one. Test printed one out and added the face surround (hopefully for the last time). I also secured it in places using dum dum. As for the ring around the rev counter, unless I find anything else suitable the old MR2 centre ring seems to work well. Again, secured via dum dum at the top and bottom.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6057_zpscjkldqwk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6057_zpscjkldqwk.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6056_zpspnn4caoz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6056_zpspnn4caoz.jpg.html)


So then I put it back in the car to see the results.  I am very pleased with it all. So the surround is packed and off to Beems for gloss black spraying to match all the other vents surrounds/pieces.  Time for a rest! LOL

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6058_zpskfk3y48v.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6058_zpskfk3y48v.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6059_zpsxfc0olj5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6059_zpsxfc0olj5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6060_zpse8ianaij.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6060_zpse8ianaij.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6061_zpstglq6ws9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6061_zpstglq6ws9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6062_zpsrigs8erv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6062_zpsrigs8erv.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Georgelooney on August 15, 2015, 07:25:03 AM
Looks great Paul, wish I had your skills
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 15, 2015, 09:51:57 PM
Update on the glove box project. The S type glove box arrived today so I set to work on taking it apart. It all comes apart easily. From the inside remove the cover for the handle and then undo the 4 start bolts that hold it in. I then used the S type door hole to make a template and then cut the hole in the MR2 glove box, lower down on the sloped part.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8886_zpsz1qnjpq7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8886_zpsz1qnjpq7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8887_zps00htonui.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8887_zps00htonui.jpg.html)


So here is the new handle in place on the MR2 glovebox

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8888_zpscsbjg5tg.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8888_zpscsbjg5tg.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8889_zps4zcs2vqs.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8889_zps4zcs2vqs.jpg.html)


Next I thought about how to secure the handle. I took the old internal piece on the s type door and cut away the below area. This means I could secure it exactly the same way in the MR2 door.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8890_zpseu2ikfyz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8890_zpseu2ikfyz.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8891_zps70jh01qv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8891_zps70jh01qv.jpg.html)


It needs tidying up a bit but you get the idea. I will spray it black so it blends in more with the MR2 glove box internals

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8892_zpshtjxi43e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8892_zpshtjxi43e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8893_zpshxoenqag.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8893_zpshxoenqag.jpg.html)


By reusing this bit means I could also reuse the cover that hides the handle internals

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8894_zpsusnuixdq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8894_zpsusnuixdq.jpg.html)


So to test it out -  Pretty pleased with it. It looks weird with the 2 handles there and the jag handle does seem to protrude a bit, but once the rest of the glovebox door is covered in leather it will merge in further, and the leather will be more of a light black colour like the handle

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8895_zpschyzp0ie.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8895_zpschyzp0ie.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8896_zpso3yurp1e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8896_zpso3yurp1e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8898_zpsyr8mqroe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8898_zpsyr8mqroe.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8899_zpsb8g28ddc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8899_zpsb8g28ddc.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: MADMAN on August 15, 2015, 09:59:16 PM
could you not recess the Jag handle so it fit,s flush ?
MADMAN
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 15, 2015, 10:29:53 PM
Hey Steve
Yes I probably could do that. I could even use the old jag door as this has a recessed bit in it aswell. Chop it up and bond it from the inside of the mr2 glove box. I'll have a think. Gonna have a few days off now as I have gone mod crazy in the last 6 days. This time last week I hadn't even thought about glove boxes and open faced instrument panels. Lol. A lot can happen in an week!

Cheers
Paul
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on August 16, 2015, 05:23:33 AM
Great stuff as always.
Car is looking fantastic.
On instrument pod, I put a clear piece of acrylic as an outer shield to spot dust getting to it and easier to keep clean. Just a thought for you to consider.
Keep the mods coming.  :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 16, 2015, 07:11:43 AM
Thanks Rudy, yes i plan to do that. I've already mocked up the template for it and the acrylic is on order. Even sized up the hole for the speedometer reset knob.  ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 16, 2015, 10:23:56 PM
Well I didn’t really keep my word in having a few days off. It took about 5 seconds for me to decide the sink the handle into the door. So this morning I took the old jag door and cut out the recessed area. The plan was to bond this on the inside of the MR2 door and then enlarge the hole so the handle sunk into the recess. It worked out pretty well. I drilled two holes and bolted the jag recessed piece in pace while I sized it all up and then bonded it. The bolts worked liked clamps. Then I removed the bolts and will fill in the holes later.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6099_zpsg8mgkhaw.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6099_zpsg8mgkhaw.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6100_zpsstexrpec.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6100_zpsstexrpec.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6103_zpsm2igxbu7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6103_zpsm2igxbu7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6106_zpsqzgy7htj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6106_zpsqzgy7htj.jpg.html)


Once I have tidied it up and the leather is on it will look a lot neater and it can sink even further into the door if needed.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6108_zpsnaq6frmu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6108_zpsnaq6frmu.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6109_zps53ejre7o.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6109_zps53ejre7o.jpg.html)


On the car – can hardly see it now from most angles and looks a lot more factory

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6110_zpsuoxeiyoz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6110_zpsuoxeiyoz.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6113_zpsdj4ec1pk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6113_zpsdj4ec1pk.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6114_zpsishr5k4w.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6114_zpsishr5k4w.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6115_zpshjmpolbq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6115_zpshjmpolbq.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 19, 2015, 07:49:06 AM
 ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 19, 2015, 08:34:08 AM
.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 19, 2015, 08:35:41 AM
.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 19, 2015, 08:37:03 AM
.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 19, 2015, 08:47:32 AM
.
Title: Re: Paul's 4thirty Build
Post by: Georgelooney on August 19, 2015, 03:32:17 PM
Great paintwork I'm assuming beemaman painted them? Top class work Paul
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 20, 2015, 06:44:00 AM
Yep he did. This is certainly something i couldn't have done myself. As these are big parts of the interior they need to be 110%.  ;D

Here's the speedo surround all prepared ready for primer.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 20, 2015, 07:11:26 AM
And now that this thread (the bible/the instruction manual/the holy grail - call it what you will  ;D ) has reached 100 pages is just like to say thank you to all those people who have helped me along the way. I've met some very nice people though this whole project/experience who I am proud to call my friends. You know who you are!

I know I stopped tracking the hours (and cost) back in July 2014 for my build as the bulk of the build was done. But as most car builders know these cars are never truly done. There is always something to modify, tinker with and improve on with these cars. I've got plenty more mods/jobs to do with the car over the coming months so here's to the next 100 pages! Lol. I hope you've enjoyed the journey so far.

Paulie.  ;D
Title: Re: Paul's 4thirty Build
Post by: beemaman on August 20, 2015, 11:15:12 AM
its a great build paul and it helps so many people building there cars.if it wasnt for people like you and al the other guys who have build threads etc we would need more help,even ive been on build threads to check things out etc

keep up the great work and im sure your interior will look as good as factory :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 28, 2015, 11:04:08 PM
After a couple of weeks break from tinkering, on Thursday I started back on the glove box project. In order to secure the handle properly I trimmed down the interior part from the jaguar part and then bonded in place. This way the handle goes in the sunken part and is secured using the original screws from the back
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 28, 2015, 11:08:14 PM
Also started on the bracket to lower the catch. I've decided to use the original jag catch part aswell but it needs to sit lower as the handle is lower. I mocked up and then drilled and bolted leaving big holes for adjustment.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 28, 2015, 11:11:22 PM
Finally started to size up the catch on the car. I plan to bolt it to this cross brace metal piece which actually is where the mr2 catch hangs from. I sized it up and then removed from the car for drilling.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 29, 2015, 09:48:30 PM
Bit more work done on the glove box today. Drilled various holes for the brackets and fitted up. Very pleased to say it turned out right first time. I made the brackets fully adjustable and bolted all in place with large repair washers. Once I was happy I sprayed the bracket black and then thread locked it all in place.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6297_zpsopipbwyq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6297_zpsopipbwyq.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6298_zpsnyofos48.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6298_zpsnyofos48.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6299_zpsa5jcpuac.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6299_zpsa5jcpuac.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6300_zpsm1z0qyxb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6300_zpsm1z0qyxb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6301_zpshknmtdxt.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6301_zpshknmtdxt.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6302_zpswkppgagb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6302_zpswkppgagb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6303_zpsy74owfew.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6303_zpsy74owfew.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6309_zpsndoivi4y.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6309_zpsndoivi4y.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6311_zpsy1jho9p5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6311_zpsy1jho9p5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6312_zpseovfuupu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6312_zpseovfuupu.jpg.html)


I also removed the MR2 handle and filled in the space and smoothed down. I then sprayed it black to get the full effect of what it would look like

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6313_zps6ts8gzp3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6313_zps6ts8gzp3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6314_zps8ywxclsw.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6314_zps8ywxclsw.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6317_zpslm7kipqf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6317_zpslm7kipqf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6316_zpsxddfn9ur.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6316_zpsxddfn9ur.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6315_zpsml8wsux8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6315_zpsml8wsux8.jpg.html)


And here’s a video of it all working - click on picture to view

(http://i1315.photobucket.com/albums/t597/pjlucas1/th_IMG_6318_zpsx7li4vhf.mp4) (http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6318_zpsx7li4vhf.mp4)
Title: Re: Paul's 4thirty Build
Post by: Lee22 on August 29, 2015, 10:08:56 PM
Well done Paul,

Brilliant as always mate  :D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on August 30, 2015, 10:43:32 PM
Cheers Lee. I'm pretty pleased with it so far

Had to share this little gem with you guys today. On my open faced speedo I was on the look out for a suitable ring for the Rev counter. I had planned to use one of the silver rings I had on the Mr2 surround I had but then found this while on holiday in Norfolk 2 weeks ago

It is basically a small cake tin for £3.50. I took a gamble as it looked the right size and today I set about back trimming it. Fits pretty well I think.   ;D

Title: Re: Paul's 4thirty Build
Post by: Furrari on August 31, 2015, 10:11:02 AM
That is amazing.   

On other site I saw somebody sinking tail lights into the rear panel using cat food bowls.

The finish seems to only be limited by ones imagination.
Title: Re: Paul's 4thirty Build
Post by: Lee22 on August 31, 2015, 10:20:06 AM
Sit's pretty well, Paul....?

Looks spot on to me... What a great find, you couldn't get the size more accurate.

Well done. ;D
Title: Re: Paul's 4thirty Build
Post by: MADMAN on August 31, 2015, 05:47:01 PM
Spot on M8
MADMAN 8)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 06, 2015, 07:22:10 AM
Bit of a dash update

The nice shiny dash bits have arrived back from Beems – looking all lovely and gloss black!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6360_zpsfy5vozwt.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6360_zpsfy5vozwt.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6361_zps9ikivcpa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6361_zps9ikivcpa.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6362_zpswlpnkawy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6362_zpswlpnkawy.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6363_zpsn9suium8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6363_zpsn9suium8.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 06, 2015, 07:25:59 AM
I also picked up the top dash from the trimmer on Saturday. I must say he has done a fantastic job, especially with the stitching around the passenger airbag area. I have never seen it done this way before and I love it. I also asked him to cut out a section on the dash that would enable me access to the new glove box mechanism easily. The hole is covered by the fake air bag cover so you’d never know

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6370_zpsi4yelqqk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6370_zpsi4yelqqk.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6371_zpsocphxmw9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6371_zpsocphxmw9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6372_zpsgetdxc1r.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6372_zpsgetdxc1r.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6373_zpsqbpauty4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6373_zpsqbpauty4.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6374_zpsxgygxwtb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6374_zpsxgygxwtb.jpg.html)1

I also dropped off the glovebox as well for him to do in the same leather.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 06, 2015, 07:37:48 AM
So I started preparing the MR2 dash for the bonding of the DNA dash. First I took out the MR2 passenger air bag cover and cut a hole in it and then bonded it to the MR2 dash permanently. I thought about not bothering with it at all, but it does give more surface area for the DNA to stick to.  I also then bonded up the flip drawer section in the middle of the MR2 dash as well.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6376_zps0qbwvfap.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6376_zps0qbwvfap.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6375_zpsnydjlqvw.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6375_zpsnydjlqvw.jpg.html)


So then it was time for take the plunge and bond the main part on permanently. I had thought about just using dum dum to secure it, but after trying it, it just didn’t work. The dum dum was too thick in various places and didn’t stick well to the leather bits so, good old Stikaflex saved the day.

Preparation here is the key, and I did a number of trail runs to ensure exactly where I was going to put the bond. Also have plenty of wipes available in case of any mess, and have the weights handy as well. I found actual gym weights are perfect as they are very heavy but also thin, so you can push them right up to the bottom of the windscreen. Left overnight to set


(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6378_zpstwyvozds.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6378_zpstwyvozds.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6379_zpsdxnf5tea.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6379_zpsdxnf5tea.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6380_zpsenwzwcyd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6380_zpsenwzwcyd.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6382_zpso9pknk8a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6382_zpso9pknk8a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6383_zps4f5bhxdj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6383_zps4f5bhxdj.jpg.html) 
Title: Re: Paul's 4thirty Build
Post by: beemaman on September 06, 2015, 08:44:28 AM
Cracking job Paul it looks fantastic mate :) one great looking car you have there and all your work too :) well done buddy :)
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on September 06, 2015, 09:10:44 AM
Looking great mate.
Just a reminder. You will need to relocate the hazard warning lights switch before you fit the vent cluster.
Also you might need to trim that section due to the centre vent.
If memory serves me right, that's what I had to do on mine.
Great looking interior and car.
Well done. :)
Title: Re: Paul's 4thirty Build
Post by: Georgelooney on September 06, 2015, 09:51:33 AM
Looks amazing mate, your car has to be one of the best 430 replicas in the UK
All the hard work sure has paid off
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 06, 2015, 08:53:25 PM
Thanks for the great comments guys. Means a lot

Thank Rudy. I had moved the hazard switch to the lower dash a few months ago. Mark kindly gave me another mr2 switch so I left the original in place and just extended the wiring down.  I had trail fitted everything up previously and as I didn't fit the scudo bezels the vents don't have to go as far back.

So this morning took all the weights off and had a look. Pleased to report it was all nice and solid. Added some more Stika flex in a few other areas just in case

Next I swapped all the dial backs etc on the HVAC cover I had to the other I had painted gloss black and fitted it to the car

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6385_zpsf6tak2da.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6385_zpsf6tak2da.jpg.html)



Then I bonded on the outer vent surrounds using Stika flex again and held in place with tape.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6386_zpsqpp1whoi.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6386_zpsqpp1whoi.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6388_zpsuktosofg.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6388_zpsuktosofg.jpg.html)


For the centre vent surround I used double sided tape for the top part and the lower part is secured with the bolts and washers on the brackets I had made for it so it is remove able if needed. Seems very solid but only time will tell.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6393_zpsjrms1og3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6393_zpsjrms1og3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6394_zpsg6wy0dcz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6394_zpsg6wy0dcz.jpg.html)


So all that was left to do was pop the rings on the vents and place in the surrounds. Used very small pieces of dum dum to keep the vents snug in place where needed.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6396_zps6t4fzwm9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6396_zps6t4fzwm9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6397_zpsk4q9znyk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6397_zpsk4q9znyk.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6398_zpsj5adgkaf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6398_zpsj5adgkaf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6399_zps3uxmsd8l.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6399_zps3uxmsd8l.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6406_zpszbsyhyud.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6406_zpszbsyhyud.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6404_zpsrzqfk98i.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6404_zpsrzqfk98i.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6403_zpsjxhddhqc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6403_zpsjxhddhqc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6400_zps8bxgxz1t.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6400_zps8bxgxz1t.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6401_zpsj2sgy4am.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6401_zpsj2sgy4am.jpg.html)



So basically it is done. What do we think?
Title: Re: Paul's 4thirty Build
Post by: Georgelooney on September 06, 2015, 09:25:33 PM
Looks OEM well done Paul. Hope to see your car at one of the shows next year :)
Title: Re: Paul's 4thirty Build
Post by: 360MKbuild on September 06, 2015, 09:32:13 PM
Looks fantastic Paul, you know I was itching to see the dash after all the extra changes (console, stereo etc) and fitted so quickly!!!. Right let's think on next project (that little voice pay back time  ;D ;D ;D )
Title: Re: Paul's 4thirty Build
Post by: ET on September 07, 2015, 01:32:11 PM
Looking great as usual Paul - I always enjoy seeing your latest 'project' - keep up the good work! Eric :) :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 07, 2015, 09:09:40 PM
Looks fantastic Paul, you know I was itching to see the dash after all the extra changes (console, stereo etc) and fitted so quickly!!!. Right let's think on next project (that little voice pay back time  ;D ;D ;D )

As you know I've got loads on things on the go/planned/ideas. Here's a few

Finish glove box
Finish open faced speedo
Retrim steering wheel in same Napa leather
Wind diffuser
4th brake light
Fuel cap

Always something to tinker with lol  ;D

Title: Re: Paul's 4thirty Build
Post by: rudycob1 on September 07, 2015, 11:35:48 PM
Paul always great ideas and an inspiration to others.
What do you plan with the 4th brake light and wind diffuser.
Interested to know your line of thought. :)
Title: Re: Paul's 4thirty Build
Post by: ferrari feb 14 on September 08, 2015, 08:16:52 AM
Looks fab Paul ,as allways mate and finishes it all off nicely , jd
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 11, 2015, 09:46:39 PM
Just a quick update tonight. This week I worked on securing the fake passenger airbag. Went down the magnet route. Bought a pack of magnets and then bonded to air bag and dash. It is now is held firmly in place but still remove able if need be. Also added my race sticker to speedo. Bought some a4 sticky printer paper and printed and cut out and stuck on. Simples. glove box  pick up tomorrow.  ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 13, 2015, 07:57:52 AM
Just a couple of picture updates:

Speedo surround all primed ready for painting:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6457_zpsbj4zhqy3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6457_zpsbj4zhqy3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6456_zpsje8jbr6f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6456_zpsje8jbr6f.jpg.html)


Also did a quick mod on the fuel cap. I bought a replacement one off eBay and sprayed it silver, and then added a shield to it. Looks a lot better compared to my original one. I just need to paint the inside of the petrol flap as it is looking a bit shabby.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6432_zpsqi0lcdu6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6432_zpsqi0lcdu6.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6434_zpso1gngvfk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6434_zpso1gngvfk.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6436_zps4tef7s4r.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6436_zps4tef7s4r.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6437_zps0e0rrsfh.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6437_zps0e0rrsfh.jpg.html)

 (http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6438_zpsuuti6kr4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6438_zpsuuti6kr4.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6439_zpskl28lgmt.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6439_zpskl28lgmt.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 13, 2015, 08:01:07 AM
Finally, I picked up the glove box yesterday. Very pleased with what the trimmer has done. He’s padded it out a bit so it doesn’t sit flush with the rest of the dash, but it makes a bit of a feature out of it. Red stitching allround with a double one at the top.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6444_zpsogxrprfb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6444_zpsogxrprfb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6445_zps8dtvnhiv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6445_zps8dtvnhiv.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6446_zpsgksfiqsa.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6446_zpsgksfiqsa.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6449_zpsde2ekwvy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6449_zpsde2ekwvy.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6451_zpsb7yuf0zz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6451_zpsb7yuf0zz.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6453_zpszg9cujmg.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6453_zpszg9cujmg.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Lee22 on September 13, 2015, 04:53:01 PM
You have a very fast trimmer Paul.
Looks
Like he's done a good job too..!

Not much more you can do now mate, surely
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 13, 2015, 06:32:38 PM
You're right. Not alot else I can do tbh. Just need to start enjoying the car more. Always on the look out for more mods and ideas. I've spoken to complete kit car magazine and hope to get a feature done soon.

Title: Re: Paul's 4thirty Build
Post by: Lee22 on September 13, 2015, 11:06:23 PM
You could always come up for the weekend and show me some of the mods first hand.... ;D

I'm desperate to get my centre console changed... I hate mine...!
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 18, 2015, 09:10:56 PM
.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 19, 2015, 08:15:32 AM
speedo surround painted - hopefully it will be home today

Title: Re: Paul's 4thirty Build
Post by: cheets on September 19, 2015, 02:30:56 PM
:) it looks good Paul so what is going to be the next job :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 20, 2015, 08:11:24 AM
LOL Mark, the list is still very long! Probably the 4th brake light idea I have
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 20, 2015, 08:14:45 AM
I thought people might find this interesting. I was showing a mate photos of the real vs DNA 430 side by side. Dare I say the DNA looks better? More proportioned? But then, I am biased! LOL  ;) ;) ;)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 20, 2015, 08:54:35 AM
Speedo surround arrived back from Beems on Saturday. Again it looks fantastic. Beems has done a top job. Thanks Matey.

So the next job was to cut the Perspex out for the screen to put in place. I had previously made some templates out of cardboard so it was just a case of cutting it out. I used 1mm clear Perspex and this is perfect, as it is the same thickness as the original MR2 stuff. 2mm is just too thick for this.

I had bought 5 sheets of A3 1mm Perspex, in case I mucked it up. Luckily it turned out right first time. A word of caution, when you cut plastic like this with a jigsaw, you want to use a special blade. The blade to use is one for glass/ceramic tiles. These blades are Tungsten Carbide. If you just use a normal jigsaw blade the plastic gets really hot and melts back together.

So I cut out the Perspex screen and then used dum dum to fix it securely in place. Also don’t forget to carefully drill the hole for the trip computer reset knob that sticks through the Perspex.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6507_zpsldphtexs.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6507_zpsldphtexs.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6508_zpshkio2ocd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6508_zpshkio2ocd.jpg.html)


Previously I had made a surround out of black plastic to sit slightly under the dial backs to hide the gap created by doing the open faced speedo. The problem I discovered with this, was as the plastic was quite thick, it lifted the dial backs up slightly at the edges. The made some of the needles stick a bit as the dial back was higher in some places and caught the centre of the needles and stopped them moving as freely. So what I did is made this surround out of black cardboard instead. This is much thinner and the problem now has gone

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6514_zpsz3q8uc08.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6514_zpsz3q8uc08.jpg.html)


It also gave me a chance to position the rev counter silver ring better and secure with dum dum again.

So then it was just a case of outing it back on the car. Job done!


(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6510_zpsjs82f5pc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6510_zpsjs82f5pc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6517_zps4expexy3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6517_zps4expexy3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6516_zpsq7r1jzfy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6516_zpsq7r1jzfy.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6515_zpsnbgnhi4r.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6515_zpsnbgnhi4r.jpg.html)

I have decided I am not going to have the Speedo top cover on the car. I think it looks better without and shows the gloss black much more and the cover does tides to make the speedo hidden more.
Title: Re: Paul's 4thirty Build
Post by: Georgelooney on September 20, 2015, 11:29:14 AM
Stunning Paul
Title: Re: Paul's 4thirty Build
Post by: Lee22 on September 20, 2015, 11:19:18 PM
Beautiful, stunning...

Looks brilliant mate..!

I bet your really pleased

Lee
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 21, 2015, 10:10:43 PM
Thanks for the kind comments guys. Yes I am very pleased. But no time for relaxing. It's onto to the next interior mod!
Title: Re: Paul's 4thirty Build
Post by: cheets on September 21, 2015, 10:24:21 PM
So come on what is that going to be and tell me more about the brake light number 4  :)

Mark
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 22, 2015, 06:41:13 PM
So next mod is modifying thr rear glove boxes and putting in 2 speakers between the seats. Something similar to what Rudy has done.

I plan to chop down the doors so they are not as wide and fill the gap with a piece of mdf that houses the speakers. The mdf would be shaped slightly to make a feature of it and then covered in the same black leather with red stitching. The doors would then close up next to it. Would prob cover doors in black carpet so they blend in better. I have already bought the speakers. I plan to make the mdf piece remove able if needed and will until use the holes where the door bolt to. Speaker wires can run underneath the centre console and carpet up to the radio easily. It's all 360mk's fault for giving me the idea. Lol

4th brake light mod will be a led brake light that is mounted behind the rear diffuser grill. It will be bolted to the rear bumper bar. I already have 2 holes in the bumper bar that have riv nuts in them so should be and easy enough mod to install.

I am not going down the flashing brake light route as can't be arsed with the potential trouble from the boys in blue.  So there you go!

Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 22, 2015, 10:34:01 PM
Started the rear speaker project tonight. Just a mockup with some hardboard to use as a template.
Title: Re: Paul's 4thirty Build
Post by: cheets on September 22, 2015, 10:51:59 PM
nice work bud your just to fast i had the same idea but not got there yet lol  :)
Title: Re: Paul's 4thirty Build
Post by: Furrari on September 23, 2015, 10:23:56 AM
The MX5 incorporates speakers in the headrests of the seats so you can hear the radio over the wind noise.  Anybody thought of doing that.?
Title: Re: Paul's 4thirty Build
Post by: cheets on September 23, 2015, 03:39:05 PM
On not going that way as think it will spoiled the look of them and as well will try to do it as near to the real thing as i can wen i get ronde to it :)

Mark
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 25, 2015, 07:22:03 PM
So as it is my birthday, I thought I’d treat myself and start the wiring for the rear speakers. I took the centre console off and the lower radio surround to exposure the wires. I had looked at a wiring diagram for the MR2 and couldn’t see any connections for rear speakers so I just branches the extra wires off the after-market radio wiring loom before they went into the MR2 radio connections/wires.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6551_zpsree5iyqo.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6551_zpsree5iyqo.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6552_zpsvp2q81nf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6552_zpsvp2q81nf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6553_zpsdpc7p6os.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6553_zpsdpc7p6os.jpg.html)

Tested them all, and all working fine!
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 25, 2015, 08:07:52 PM
So next it was time to take the plunge and start cutting up the glove box doors. I replicated the template I had made in 18mm MDF, marked up the doors and cut them! No going back now

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6555_zpsfucagg5p.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6555_zpsfucagg5p.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6557_zpshwqqjdcb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6557_zpshwqqjdcb.jpg.html)


I fed the wires along the transmission tunnel and drilled a hole in the rear storage bins and fed them thru

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6556_zpsgmu8oyio.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6556_zpsgmu8oyio.jpg.html)


(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6557_zpshwqqjdcb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6557_zpshwqqjdcb.jpg.html)


Next was fitting the MDF in place. What I want to do is be able to remove the MDF panel if I need to, so I didn’t want it bonded in place permanently. I bought some butt hinges and tried to utilize the spare glove box door bolting holes, but it didn’t work. Then I had the idea to use the original hinged part from the cut off bits from the doors. A bit of trial and error placement and then I screwed them to the back of the MDF.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6559_zpsntzstyud.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6559_zpsntzstyud.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6558_zps7uxcjv11.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6558_zps7uxcjv11.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 25, 2015, 08:25:33 PM
With still and hour tinkering time left, it was time for the speakers! After careful placement and measuring I cut out the hole for the top speaker.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6560_zpsit5yjryb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6560_zpsit5yjryb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6561_zpsos0duuhl.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6561_zpsos0duuhl.jpg.html)


Tested it and all works fine, and then it was onto the bottom one. With this one I obviously had to cut away some of the hinge plastic. I then added some more screws to the hinge plastic for extra strength. I placed the bottom speaker as high as possible otherwise the magnet on the inside ‘could’ hit the bottom of the storage bins.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6564_zps4jwjwmzl.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6564_zps4jwjwmzl.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6565_zpsel4dw0za.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6565_zpsel4dw0za.jpg.html)


Wired it all up and went out for a birthday lunch. The sound fills the car much better as it is really next to your ears. Very pleased so far.. I have taken the speakers out now so I can work on the shaping of the MDF.

I am going to extend the vertical sides down into the glove box on the MDF and slope the edges. It will then be covered in black nappa leather with red stitching to match the rest of the interior. I will cover the glovebox doors in black carpet.

I also need to then create a bracket so the MDF can be secured at the top. I plan to piggy back off the bolts that are used to secure the catch that locks the roof, extend then down and the bolt the MDF to the brackets. Ideally I’d like to be able to bolt it at the top without bolts showing on the outside of the MDF/Leather but we’ll have to see how that goes. I love the speakers as the black and silver really goes with the rest of the interior.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6566_zpsec0tbwsw.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6566_zpsec0tbwsw.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6568_zpshzwvcm0k.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6568_zpshzwvcm0k.jpg.html)

What do we all think?  ;D
Title: Re: Paul's 4thirty Build
Post by: 360MKbuild on September 25, 2015, 08:34:47 PM
Brilliant work Paul ;D, as you know going to do something similar,
Title: Re: Paul's 4thirty Build
Post by: ferrari feb 14 on September 26, 2015, 09:06:12 AM
Looks fab mate great work as allways ,jd
Title: Re: Paul's 4thirty Build
Post by: cheets on September 27, 2015, 02:28:46 AM
liking it bud :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 27, 2015, 07:02:53 PM
Bit more work done on the speaker box. I added some strip wood along the sides to create depth, did a bit of filling and then shaped the edges to make it look more interesting. I plan to drop it off at the trimmers next Saturday.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6579_zpsxlbb5v6b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6579_zpsxlbb5v6b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6581_zpsrplghmlv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6581_zpsrplghmlv.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6582_zpstnsczzhi.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6582_zpstnsczzhi.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6583_zpszkp20dwu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6583_zpszkp20dwu.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6584_zpsopssmztn.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6584_zpsopssmztn.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6585_zpsrvhz7wqn.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6585_zpsrvhz7wqn.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 27, 2015, 07:04:28 PM
Bolted back into the car

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6586_zpsfrvgubpv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6586_zpsfrvgubpv.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6587_zpsck65zb1f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6587_zpsck65zb1f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6588_zpszummncmi.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6588_zpszummncmi.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6589_zpssqnuqdbn.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6589_zpssqnuqdbn.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6590_zpsvjuczqpj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6590_zpsvjuczqpj.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 27, 2015, 07:25:34 PM
Previously I had mentioned another mod I was planning on doing – the 4th brake light. This sits behind the rear diffuser grill and is bolted to the rear bumper bar via a bracket I have made.  When building my car I had sunk 2 rivnuts into the bumper bar to secure my Anderson clamp when not in use, so these where perfect to mount the brake light bracket on as well.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6591_zpsjfxebz2n.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6591_zpsjfxebz2n.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6592_zpsqyznsmur.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6592_zpsqyznsmur.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6594_zpsdvgvzl38.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6594_zpsdvgvzl38.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6595_zpsyapwdumv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6595_zpsyapwdumv.jpg.html)


I got the brake light off eBay. These are all made in China. I think it was meant to be a flashing one, but it doesn’t flash. Just as well as I can’t be bothered with the potential trouble it could bring from the Police. I had bought a few of these lights before, in different shapes but this one is bigger and has 15 nice LED’s on it.

With all these brake lights, the wires are really thin and flimsy. I didn’t like that so I have wrapped a thicker wire to the thin one and then covered all in amalgamation tape so it is more heavy duty. I have run the wiring up into the engine bay ready for connection later.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6597_zpsmbvvgxwp.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6597_zpsmbvvgxwp.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6598_zpsowkkn0yj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6598_zpsowkkn0yj.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6599_zpshrhwortu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6599_zpshrhwortu.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on September 27, 2015, 07:28:47 PM
I sprayed the bracket black to hide it and then bolted in place. I made the mounting holes nice and big so I have a lot of adjustment to get the light just right behind the grill

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6600_zpsqvmqo4wm.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6600_zpsqvmqo4wm.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6601_zps4p55fn7g.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6601_zps4p55fn7g.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6602_zpsaskcphaz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6602_zpsaskcphaz.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6604_zpsfdj3hdxc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6604_zpsfdj3hdxc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6605_zpsqy0du0kr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6605_zpsqy0du0kr.jpg.html)


Upon reflection, the metal I used for the bracket is quite thin and the light ‘could’ vibrate when driving the car. So I will add some side supports to the bracket to strengthen it.  But below you can see how it looks and the targeting end result

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6606_zpspstqhpsi.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6606_zpspstqhpsi.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6607_zpsknduq8lk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6607_zpsknduq8lk.jpg.html)

Hope you like it!  ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 03, 2015, 06:02:28 PM
Well the forum is very quiet at the moment, so time for an update….

I dropped the speaker pod off at the trimmers this morning. Going for the usual: Black nappa leather with red stitching. The stitching will just go lengths way from top to bottom. Should be ready to pick up next week. On the way to the trimmers I was flashed at by a real 360 Modena and then a lambo. I did smile to myself.  ;D

Before I left I finished off the 4th brake light. I ordered some side brackets off eBay and bonded them in place. This gives the l-shaped bracket more strength. I then sprayed it all black again.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6627_zps4izcdmu6.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6627_zps4izcdmu6.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6632_zpsbi9flvdj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6632_zpsbi9flvdj.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6634_zpsggsys6bd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6634_zpsggsys6bd.jpg.html)


Bolted it back all in place and then tackled the wiring. My 3rd brake light was playing up, so I just went back to basics and redid all the wiring. All working fine now. The little black box I have in the engine bay which used to house the flashing unit,  I used as a junction box to connect all the wires together.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6637_zpso53bmaiw.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6637_zpso53bmaiw.jpg.html)


I re-laid all the wires along the inside of the body – it isn’t great as I’d rather have them out of sight underneath but I am not taking the rear diffuser off just for this. I made it as neat as I could.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6638_zpsohvoaff7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6638_zpsohvoaff7.jpg.html)


So here it all is working -  because only 3 brake lights will never do!  8)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6642_zps34uwhmw5.png) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6642_zps34uwhmw5.png.html)
Title: Re: Paul's 4thirty Build
Post by: cheets on October 04, 2015, 02:20:24 AM
all looking good bud don't think i will be doing this mod as think that my color will let the  3rd brake light stand out lol
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 04, 2015, 08:14:36 AM
i know what you mean matey - the red will look great against the tiffany blue  ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 05, 2015, 11:22:28 AM
So the next mod I am thinking about is a heads up display (HUD).

There are plenty on eBay to choose from, so I have bought one. I didn't go for then cheapest and bought it from a UK seller in case it doesn't work so I can return it

Most of them connect to the car via the ODBI connection

The challenge will be where to mount it so it works but doesn't look rubbish.

The one I have bought is around the size of an iPhone 5s. A good place to mount this would be right at then front of the dash board on the air vents. It should fit perfectly in the gap between the windscreen and the start of the dna dash cover. It is only 12.5cm wide so won't block the vents too much. The question then is is it too low down on the screen to be effective? I guess you don't want them too high on the screen anyway. If it needs to have a film attached to the screen for it to work better then at least the film is lower down and in the centre of the windscreen

If the HUD needs to be mounted further back I think the only way to go would be to build a shallow tray/unit to house it.. This could again be covered in black leather/red stitching to make a feature out of it. I was even thinking of disguising it as a dash mounted speaker with a grill

Anyone else tried these HUD's?
Title: Re: Paul's 4thirty Build
Post by: Georgelooney on October 05, 2015, 11:48:55 AM
Hi Paul, I've not used then but was thinking of getting one so will be interested to see how you get on with it :)
Title: Re: Paul's 4thirty Build
Post by: MADMAN on October 05, 2015, 02:09:45 PM
So the next mod I am thinking about is a heads up display (HUD).

There are plenty on eBay to choose from, so I have bought one. I didn't go for then cheapest and bought it from a UK seller in case it doesn't work so I can return it

Rudy has one fitted, may pay you to PM him, I believe you have to start car then plug unit into the OBD socket, if plugged in on start up I think Rudy said it throws a fault code up 
MADMAN


Most of them connect to the car via the ODBI connection

The challenge will be where to mount it so it works but doesn't look rubbish.

The one I have bought is around the size of an iPhone 5s. A good place to mount this would be right at then front of the dash board on the air vents. It should fit perfectly in the gap between the windscreen and the start of the dna dash cover. It is only 12.5cm wide so won't block the vents too much. The question then is is it too low down on the screen to be effective? I guess you don't want them too high on the screen anyway. If it needs to have a film attached to the screen for it to work better then at least the film is lower down and in the centre of the windscreen

If the HUD needs to be mounted further back I think the only way to go would be to build a shallow tray/unit to house it.. This could again be covered in black leather/red stitching to make a feature out of it. I was even thinking of disguising it as a dash mounted speaker with a grill

Anyone else tried these HUD's?
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 05, 2015, 06:24:15 PM
cheers Madman

fingers crossed my one wont do that fault thing, but I'd least i'll be prepared for it

Title: Re: Paul's 4thirty Build
Post by: rudycob1 on October 05, 2015, 07:00:57 PM
Hi appal,
Like Madman said, I have fitted one to mine. Sounds like you have a similar model.
I mounted this exactly like you said and for the same reasons. You will need the film otherwise you will get double vision due to the laminated windscreen. I tucked to cable in between the dash and the windscreen and than down the side pillar so the connector came down from under the dash next to the plus in connector. Mine works great and very useful, especially to monitor speed.
The only thing is if you leave it plugged in, once you start the car, some of the warning lights stay on.
This puzzled me so I spoke to Paul at Woodsport and the reason is that the car thinks that it's doing some sort of test and causes this to happen. If you start the car first, than plug it in, all will be fine.
Paul said that there could be a way to stop this happening by putting a resistor but I did not fancy messing about with it.
Let me know how you get on.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 05, 2015, 07:06:41 PM
got any pictures of it in place matey?
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on October 05, 2015, 07:33:17 PM
Just sent you a pic via email as I cannot upload it on my iPad.
You can post it on here if you can.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 06, 2015, 07:52:32 AM
Thank you Rudy for the picture. That is exactly what I was thinking of.

I think my idea of it being mounted right at the front in the vents, while a cleaner solution it won't be the best for the displaying of the numbers. It needs to come back and actually sit on the DNA dash. I tired it with my iphone and a free HUD app that I found just displaying a speed number, and it is better there. Plus it has to go in the centre of the windscreen. If you try and put it more on the drivers side, due to the curve of the windscreen the numbers will look crooked

What I am thinking is building a housing to place the HUD in, have it covered in black leather with red stitching and then mount it in the centre of the dash. I am even thinking of getting the F430 sign embrioded on the front of it to make it a proper feature. Watch this space!  ;D

Below is the one i have bought

Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 06, 2015, 09:57:03 PM
On the off chance I spoken to the trimmer and the speaker pod was ready. Dad was in the area so kindly picked it up for me. Here it is. Looks fab.
Title: Re: Paul's 4thirty Build
Post by: 360MKbuild on October 06, 2015, 10:07:56 PM
Nice  :)

going to look lovely against the matching console, great work cant wait to see speakers in
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 08, 2015, 09:30:55 PM
Ok guys, lots to get through tonight…

Speaker pod is nearly done. Very pleased with what my trimmer has done. So before installing the speakers I fitted it back to make sure all is well

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6700_zpse5urlop4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6700_zpse5urlop4.jpg.html)


The next task was how to secure it at the top. I had the idea of mending plates secured each side by a teck screw. These can rotate and when the speaker pod is in place, I turn the mending plates so they are vertical and secure behind the rear of the roll bar carrier cover

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6707_zps8aoj9ne8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6707_zps8aoj9ne8.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6708_zpsoibxs1nv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6708_zpsoibxs1nv.jpg.html)


The beauty of this, is that it is rock solid in place, but still removable so it folds forward if I ever need it to.

Then it was time to mount the speakers for the last time.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6709_zpsot2s3apb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6709_zpsot2s3apb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6710_zpszfy4zzue.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6710_zpszfy4zzue.jpg.html)


I then fitted again and tidied up the wiring making sure it has enough slack to fold forwards if need be

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6711_zpsegekqjnz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6711_zpsegekqjnz.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6712_zpsqo6hc6ta.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6712_zpsqo6hc6ta.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 08, 2015, 09:35:00 PM
Once the mending plates were vertical you can see them sticking up below arrowed. I then covered them in dum dum to secure them further and hide the sharp edges

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6717_zpspw42oc0f.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6717_zpspw42oc0f.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6718_zpszesemqil.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6718_zpszesemqil.jpg.html)


So here it is fully installed.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6719_zpskbe995pj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6719_zpskbe995pj.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6721_zpsn6vyguod.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6721_zpsn6vyguod.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6722_zpshuvo5nfe.png) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6722_zpshuvo5nfe.png.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6723_zpsn3pmkujv.png) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6723_zpsn3pmkujv.png.html)


All I need to do now is trimmed the glove box doors and fit back. Simples! Oh yeah, and the sound is pretty nice as well!!!!  ;D
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on October 08, 2015, 09:47:36 PM
Looks fantastic mate.
And yes I agree the sound is great as I have those same speakers.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 08, 2015, 09:51:28 PM
Quick update on the HUD project. So the unit I bought arrived and tested it out. It’s quite a big one, below is compared to a Samsung Galaxy S4

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6702_zpspdivt70b.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6702_zpspdivt70b.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6704_zpsd3aor4ea.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6704_zpsd3aor4ea.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6705_zpsdlpeglyu.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6705_zpsdlpeglyu.jpg.html)

I tried it out on my Merc and it works great.

However as I said previously I wanted to mount it on the dash in a way that blended in. The plan is to build some sort of frame, and cover in leather. I wanted the frame to have sloped sides as opposed to a box and on the front slope to have the F430 sign embroiled in as I don’t have the badge on my air vent surround.

I’ve been thinking about how to make the frame, but then I had a brain wave! I could use a real picture frame and adapt it. Genius! Looked on eBay and found one, ordered and it turned up today!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6727_zpsbvr0f5ts.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6727_zpsbvr0f5ts.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6728_zpsjmrhzvkg.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6728_zpsjmrhzvkg.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6729_zpsez156zhm.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6729_zpsez156zhm.jpg.html)


I will need to raise the frame up so the connector has room, and I will probably have to widen the frame as well. Not by much – maybe 2cm so the connector has room. But that should be easy. Just cut the frame in 2 lengthways and fill in the gap.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6730_zpsamkufj12.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6730_zpsamkufj12.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6731_zpsi5qwpcvz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6731_zpsi5qwpcvz.jpg.html)

The only thing I am not sure of is always having the HUD showing, so what I might do, is disguise the whole thing as a dash speaker, and have a grill sitting on top of it and remove when driving. What this space!!!!  ;D

What do we all think?
Title: Re: Paul's 4thirty Build
Post by: Lee22 on October 08, 2015, 09:56:37 PM
Sorry to say Paul, but not my thing, I'm afraid...

But good luck with it, and I'm sure you will make it look amazing... As always
Title: Re: Paul's 4thirty Build
Post by: beemaman on October 08, 2015, 10:01:44 PM
Another great idea mate as always :) you really do think of some good ideas buddy.

You could always put a picture in there of your misuss so you remember what she looks like seen as your in the garage all the time lol only kidding mate :)

Can't wait to see it done and great job on speakers
Title: Re: Paul's 4thirty Build
Post by: MADMAN on October 09, 2015, 09:00:11 PM
How did we go on before ebay?
MADMAN 8)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 09, 2015, 11:08:18 PM
Lee - fair enough matey. I'm sure you'll love it when it's done. I'm not 100% on the idea which is why everything will be made fully removeable in case it goes wrong

Wayne - I told Jules what you said, and she wants to buy you a pint of Lemonade! "too right!" she said.  LOL

Steve - "eBay - helping people build kit cars since 1995"
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 10, 2015, 09:45:39 PM
so............

I have decided to shelve the HUD plan. I have stared at that picture frame for hours, cut it, shut it, but I don't think it will look good. I think it will spoil the dash. So I am going to leave it. I might still keep the HUD as it was only £36 and used it in my Merc

Finished off the glove box doors this morning. The inital plan ages ago was to cover them but tbh... I have just trimmed them so they fit and I am happy with that. Gave them a quick spray of dash shine once fitted. Job done. When the seats are in position you cant see them anyway!

So the interior is done and there are no more mods on my car left to do I think! I think I am done......... ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 11, 2015, 09:32:21 PM
So what's next?

Well I had thought about this in the past, and then with a fateful message to Wizard yesterday this idea came back to me!

I am going to try and motorise the opening of my rear deck!!!!   :o :o :o

Why? Well, first it would be pretty cool (I think) even if it isn't entirely necessary but second there is a more practical reaon for it

With my rear deck, when I release the catches it doesn't really pop up. This is good really as means if a catch failed then in theory it takes a lot for it to fly open when on the road. But as when I open it, I'm on one side (the drivers), I have to put my fingers under the bare fibre glass and pull it up. It is heavy and as the force is being applied from only one side, it twists slightly. Nothing major at all, but still. Then as it opens, the gas rams take over and up she goes.

What I am thinking is replacing the gas rams with Actuators. These are very common and used everywhere these days. They aren't particularly cheap either, but still - needs must.  ;D

I opened the rear deck yesterday and stared at the gas rams In theory these are the same as Actuators. Just not motorised. They push the rear deck up when they open up enough which is why I'm 90% certain this could work.

I have purchased one actuator to see if it will work. If it does I will buy another one so I have one each side.

The actuators only have 2 wires. Wire them up one way and the motor pushes the rod out. Wire up the other way and the rod retracts. So this means I also need to get an Inversion switch box so they can go both ways. This comes with a remote control so in theory once I release the catches I can just stand back and hit a button.  ;D

In terms of mounting I think it will be pretty straight forward. They come with brackets and looking at the frame on the rear deck I can attach the top part with the use of an L-shaped bracket as well using the same hole where the gas ram fits to. The one I have ordered is very close in length when open to the current gas rams.

What do we all think? Am I crazy? Will it work? Is it worth it? Potential pitfalls?
Title: Re: Paul's 4thirty Build
Post by: NYAL F430 on October 12, 2015, 07:00:42 AM
Hi Paul

Excellent  work on the car mate, I also have actuators, to be fitted to the rear deck,
Will try to fit over the winter months  :)
Title: Re: Paul's 4thirty Build
Post by: Furrari on October 12, 2015, 09:38:14 AM
Paul

What has need to do with it.  "Because you can" is all the reason you need.  The control you need is called an "H" bridge and are available cheaply on eBay.

One possible problem is that the battery is in the back and if you can't get in with the actuator due to the battery being flat ( what shape are they usually ? ) then you have a bit of a problem, or do you have external charging point.?
Title: Re: Paul's 4thirty Build
Post by: crowley on October 12, 2015, 10:10:16 AM
my only thought on this is..... is there some way of fitting a micro switch to the catches? so that when the switch is closed and the catches are engaged there will never be a power feed to the actuator motors?
Maybe a micro switch in the body that is pushed in when the rear lid is pulled tight with the catches but that will have enough room to open when you release them?

My concern would be the one day you don't undo both catches properly and you hit the motor switch to hear the sound of fiberglass cracking under stress... or worse... you or someone else flicks the switch by accident. doesn't realize what it does and you have a deck lid with the catches ripped off....

Title: Re: Paul's 4thirty Build
Post by: Furrari on October 12, 2015, 11:33:56 AM
You can get 4 Channel remote switches.  This would allow 2 pairs of "H" gate controls so how about the  realy coolness of fitting actuators at the front as well so both the front and rear panels can be operated remotely.  These controllers can be set so that they only give a current out while the fob button is pressed so switching the actuators off when the panel is fully open/ closed is not a problem.

I would fit a limit switch lighting an LED on the dash to tell you that the panel is closed to prevent any danger of not having the rear deck fully closed and opening while you are driving in excess of 69mph.  :-)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 12, 2015, 06:47:08 PM
Thanks for all the comments and thoughts guys. Makes me feel all warm inside. I'll reply with my thoughts in detail when I get home and am on the computer.  ;D
Title: Re: Paul's 4thirty Build
Post by: CdRsKuLL on October 12, 2015, 07:41:44 PM
I've got one of those actuators on my rear spoiler of my Lambo. I'm controlling it via an arduino. I don't need to measure the distance it moves as it has end stops but the one I have has a built in potentiometer so could use it to check what position its in.  I would be more than happy to develop some code / board to help out if you want.  Would love to see it part motorised.

Steve
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 12, 2015, 08:11:16 PM
So on all the points raised

My battery is now in the front. I had it relocated when I had the V6 done. Plus I have an Anderson clamp attached to the rear bumper bar which is accessible from behind the rear number plate so can charge the battery no probs.

I was thinking of having a switch between the main power supply and the control unit/actuators so I need to flick it before the actuators have power. This is a less glamorous solution than having switches on the catches which I think could be a bit temperamental.

I have extra straps to stop the rear deck coming open when driving which attach to the metal of the deck plus I think that the actuator would also work as a safety feature as I guess they can't be forced open by hand. It may mean I can do away with the straps.

So on terms of the catches not being fully open before I hit the open button. Well I guess I'd need to be very careful and have a routine to ensure all is well before I hit the open button. So release catches, ensure straps are slack and then go for it. The actuators move pretty slowly so I'd hope if something was stuck I'd realise before it was too late. I wonder how strong the springs are in the catches are anyway.

Other things i can think of is what if one of the motors fail? Well I think given where I mount then on the mr2 body I can get to the lower bracket on the actuator via taking the rear wheel off and arch liner. I could then get inside to undo the actuator from the bottom and thus open the rear deck by hand  as it wouldnt be attached to the car body anymore. Hopefully these are all extreme cases but trying to think of everything.  

What would be good is if the power to the actuators is cut when the car is in motion How do we think we could do that? I'd need a power line that is live when car is stationary but dead when driving.

As for the front bonnet being motorised aswell would need to look into that but I fear there won't be much room in there to do it or suitable mounting points.
Title: Re: Paul's 4thirty Build
Post by: cheets on October 12, 2015, 08:44:53 PM
Hi Bud i do like this think it will be something i would go with :) for cutting the power all you need to do is take a feed for the handbrake to a relay so the deck can only open wen the handbrake is on


Mark 
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 12, 2015, 10:37:51 PM
Great idea Cheets. Thanks a lot

Steve. Thanks for the offer. I might just take you up on that. 😉
Title: Re: Paul's 4thirty Build
Post by: cheets on October 13, 2015, 02:34:44 AM
That ok bud its how i have dun my deck release solenoids  was also going to fit a dead luck the same way will post pics wen i get round to it

Mark

Title: Re: Paul's 4thirty Build
Post by: Furrari on October 13, 2015, 12:13:09 PM
Good idea from Cheets but the problem is that if you are using an "H" bridge you still need power to close it even although the handbrake is on because with an H bridge all you do is reverse the polarity of the two operating wires. Interesting.

But if anybody can do it, you've got to. :-)
Title: Re: Paul's 4thirty Build
Post by: cheets on October 13, 2015, 01:51:46 PM
This how i have weird up my duck release and how i will be doing the deck lock hope you can understand what i have dun :)
Title: Re: Paul's 4thirty Build
Post by: Furrari on October 13, 2015, 03:51:17 PM
Cheets.  Second one nice and simple but won't drive an actuator.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 13, 2015, 07:11:20 PM
I'm loving the interest this subject has generated. Thanks for all the help.

"If anyone can do it it has to be me" is just the encouragement I need. Lol

I've got notification that one actuator has been posted. I'm resisting the need to buy the other and the h gate until I've tested one and set it up. Looked into the mounting of it and think I'll need some quite long L brackets on the frame so the actuator sits straight. If you look how the gas Rams are mounted they slope outwards.
Title: Re: Paul's 4thirty Build
Post by: Furrari on October 13, 2015, 08:48:18 PM
Changing angles not a problem. Self aligning spherical bearings (rose joints ) will sort it.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 13, 2015, 10:11:21 PM
So a few photos. I plan to mount at the bottom using this hole and the attach to the frame via a bracket at the top.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 17, 2015, 09:02:51 PM
Time for an update on the motorised rear deck project…

So during the week the actuator turned up and I couldn’t wait to try it. It’s a nice, heavy solid thing and as expected, if you wire it up one way, the rod comes out and then reverse the wiring, it goes back in.

So the initial plan was to see if it would work at all and not worry too much about placement etc. I am pleased to report that it did work! So I bolted it in place at the bottom and then to the L-bracket using the gas ram hole.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6789_zpskadk3g1x.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6789_zpskadk3g1x.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6788_zpstengpvnr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6788_zpstengpvnr.jpg.html)


So I tested it, and it goes up and down! I still had the other gas ram in place on the other side for safety reasons and it does move slowly, but it does do as expected. Going down was fine, but when it came back up again, it completely mangled that L- bracket I has used. See the photos below

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6797_zpsftpe2jjz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6797_zpsftpe2jjz.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6798_zpsrzogh5dz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6798_zpsrzogh5dz.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6799_zpsvgptf2dd.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6799_zpsvgptf2dd.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6800_zpsgenj9top.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6800_zpsgenj9top.jpg.html)


I took it all apart and then tested various clearances as I didn’t have it fully closed all the way down. What I did discover however is the motor on the actuator was hitting this part of the rear deck frame. Mmm  - what to do.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6801_zpscajswd2l.png) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6801_zpscajswd2l.png.html)
Title: Re: Paul's 4thirty Build
Post by: cheets on October 17, 2015, 09:08:45 PM
Nice work bud can the bit be cut out and then welded back up ?


Mark
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 17, 2015, 09:25:38 PM
don't worry Mark -  I have a plan!  ;)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 17, 2015, 09:28:19 PM
So I had 2 options: move the position of the actuator outwards or inwards.

On the outwards option, you could mount the actuator further back and higher on the red, wooden part of the DNA body and flip it around so that the motor of the actuator is at the bottom. (There is no way you could mount with the motor on the top as it would hit the rear deck from underneath.) By doing this with the motor at the bottom, it falls over the edge of the wood on the DNA kit. The issue you have now though is the rods are higher than before and there is no way the whole thing would ever close. This wouldn’t work.

So the only option is to move the actuator inwards slightly. But this means I can’t use the mounting holes I had previously. So I had a think and with various ideas discussed with Mark (cheers mate by the way for all the help) I came up with the following solution.

When you have a V6 conversion, Woodsport have to cut away part of the MR2 body. Because of this they weld extra box section to the suspension turrets. This gave me a nice triangle to mount a piece of steel on and then bolt the actuators to this.  Below is what I plan to do. I have mocked up in MDF. For those without the V6 and the extra box section, you could just have a flat steel bar all the way across the back and do it that way. I was going to do that originally but then thought of this new way.  I plan to have an extra bolt on the box section and also bond in place when fitting up for the final time. Obviously everything will be painted black so it wouldn’t be so obvious..

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6821_zps2nivjh4x.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6821_zps2nivjh4x.jpg.html)


In terms of above, the L-bracket idea doesn’t work, so I am going to bolt a piece of mild steel, 3mm box section to the frame and then the other end of the actuator bolts to this.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6803_zpsj2c73mxj.png) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6803_zpsj2c73mxj.png.html)


To test it all I got some wood which was the same size and taped some magnets to it so it could stick I place on the frame

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6813_zpszxmamdjt.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6813_zpszxmamdjt.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6812_zps9vq7aa5a.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6812_zps9vq7aa5a.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6828_zpsci3lwfiv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6828_zpsci3lwfiv.jpg.html)


I will need to drill another hole here so the box section is bolted in 2 places to the rear deck fame

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6829_zpssohnta8o.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6829_zpssohnta8o.jpg.html)


So this is where we are at. The masking tape is there to raise the actuator up slightly to simulate it position if it was attached to the frame on the rear deck

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6831_zpsawlam1ds.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6831_zpsawlam1ds.jpg.html)


And here the view from the top. You can see the wood which is the box section, but this will be painted black anyway and then you can see the silver bracket at the top of the actuator that will be bolted to the box section

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6832_zpsbpnyzojt.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6832_zpsbpnyzojt.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6833_zps3ekcriwg.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6833_zps3ekcriwg.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6834_zpsnmr5vxwi.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6834_zpsnmr5vxwi.jpg.html)


I have ordered the other actuator and the h-switch now as well. So what do we all think?
Title: Re: Paul's 4thirty Build
Post by: cheets on October 17, 2015, 09:44:10 PM
loving it :)


Mark
Title: Re: Paul's 4thirty Build
Post by: Lord Beany on October 18, 2015, 08:14:10 PM
I think you have too much time on your hands, lol.

Great work and detailed as ever for those wishing to follow suit.

Beany ;D
Title: Re: Paul's 4thirty Build
Post by: beemaman on October 19, 2015, 09:40:52 AM
i think you and lee and barry are all nutters and ile have that pint of lemonade next time i see you but ile add some beer in there too lol :)

great job mate as always you are very calculated and precise and do a fantastic job.i think your in the wrong profession buddy :)

keep the updates coming looking forward to seein this done
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 21, 2015, 05:49:30 PM
Thanks chaps. So am I. I had a big spending spree on eBay on Sunday to get all the parts etc so they are gradually turning up this week.

The second actuator has arrived and I have a feeling the h switch has turned up today. All the metal has arrived - box section and 3mm steel for the base parts.

Should get 3 hours on sat to work on it. Plan to get one side working.

Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 21, 2015, 09:35:28 PM
So the H switch has arrived. I wired it all up with the actuators and works just lovely. Should the remote fail, the H switch has a button on the unit to make them open and close as well.

Also i found these clear side repeaters on Ebay, and as I had a bad day at work yesterday, I thought I'd treat myself

Title: Re: Paul's 4thirty Build
Post by: 360MKbuild on October 21, 2015, 10:19:45 PM
Let's have a bad day everyday for an excuse to get goodies ;D really like this mod on the deck
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 26, 2015, 06:30:26 PM
All. I have bad news

I have decided to pull the rear deck project. 😔

I managed to get one side fitted up at the weekend with all the steel etc.

It pulled the deck closed but when the actuators were nearly shut they were lying almost horiztal and was pulling the rear forwards and out of shape. I thought I'd quit it before damage was done.

Sorry all.
Title: Re: Paul's 4thirty Build
Post by: Lee22 on October 26, 2015, 09:47:00 PM
Well done mate,

Didn't do any damage to the car.. ;D ;D
Title: Re: Paul's 4thirty Build
Post by: cheets on October 27, 2015, 03:36:37 PM
That is a shame it will not work bud :(
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 27, 2015, 06:42:33 PM
No damage done luckily but I did cr@p myself at one point. Last night I did have a brainwave and thought I could make it work again. But sadly I still don't think it will. Never mind. It would have been a nice to have and I'm sure I'll use the bits on something else one day.

So the only mod left on the horizon is the recovering of the steering wheel and clear side repeaters.

On the plus side my car is booked in for a magazine feature on 4th December with Complete Kit Car magazine.

It is possible that it could be a 2 part feature like Beems DN8. Part one of the build and part 2 of the finished car. It depends whether the build photos are good enough. As you know I took hundreds of photos but most of them I resized smaller to put on the forum. The mag needs really high resolution ones. I have a few left luckily so watch this space. 👍
Title: Re: Paul's 4thirty Build
Post by: Lee22 on October 27, 2015, 06:45:00 PM
Well done Paul, will look good in the mag mate...

Re-covering the Steering wheel... Let me know how you get on with that mate please, as mine is VERY Shiny... and needs doing...

Lee
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 27, 2015, 06:54:05 PM
Yeah. I am going to see if my man can reshape the spoke bits at 3, 6 and 9 so they match the silver plate better
Title: Re: Paul's 4thirty Build
Post by: Lee22 on October 27, 2015, 07:14:10 PM
Original F430 wheel Paul?
what's your thoughts???
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 28, 2015, 08:27:55 PM
Probably just make the mr2 wheel a little fatter and have the spokes the same size as the silver plate parts. I'm sure it's possible.
Title: Re: Paul's 4thirty Build
Post by: Lee22 on October 28, 2015, 09:49:37 PM
Ya, I think your right Paul, it's all about the Girth...!

Well that's what the wife says...! ::)

In all seriousness, it's something I would definitely want doing, so if you find someone willing to do it, let me know as I'll want mine doing too...
Title: Re: Paul's 4thirty Build
Post by: Paul79 on October 31, 2015, 09:46:14 AM
Quick up on the indicators. Fitted up drivers side (as can't get to the passenger side yet as in the garage) Very pleased with these. I had to get some orange bulbs off eBay as Halfords didn't do them. Before and after below:



Title: Re: Paul's 4thirty Build
Post by: CdRsKuLL on November 01, 2015, 09:08:10 AM
Very nice fella, its little touches like this that makes it your own. :-)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 01, 2015, 07:10:45 PM
Thanks Steve. Took car out today so I could fit up the other side.
Title: Re: Paul's 4thirty Build
Post by: cheets on November 02, 2015, 12:55:21 AM
Looks rely good buddy can not what to see it for real with mine next to yours :)
one day

Mark
Title: Re: Paul's 4thirty Build
Post by: MADMAN on November 02, 2015, 10:05:11 PM
Looks the dogs M8.
But what is that black thing on top of your car???? ;) ;)
MADMAN 8)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 07, 2015, 10:34:48 AM
morning peeps - hope you are all well on this lovely windy and rainy day!

I need a favour. I am planning a head light upgrade/overhaul soon (after the magazine photo shoot) and i am thinking about fitting some angel eye type ring lights and some switch back daylight running lights that also double up as an indicators

what i am thinking is placing the angel rings directly on the glass on the main headlight glass and having these as side lights. What i need is the approx measurements of the red and yellow lines below if anyone has their lights in pieces at the moment?

any thoughts on this, whether it is doable? I guess i could bond the angel eye directly to the glass with a couple blobs of superglue? the angel eyes seems to have tabs on them as fixing points. Rudy, i know you have done something similiar. what did you do?

thanks all x

Title: Re: Paul's 4thirty Build
Post by: rudycob1 on November 08, 2015, 12:38:15 AM
Hi Paul,
My approach was different and very easy once I figured it out.
I used LED strip light same as we use for the side lights. These fit into the recess in the headlight plastic unit were the headlight pushes into. So I placed the led strip with a bit of double sided tape and had them facing upwards. Than fitted the headlight as per normal. By doing this the LEDs reflect onto the glass of the headlight and give a 3D illusion. Very effective as it looks like the LEDs are in the headlight. Than just wire with the sidelights. Hope this helps.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 08, 2015, 06:50:00 PM
Thanks Rudy. I know exactly what you mean and I'm gonna do the same. The mounting of the Angel eyes above would be much more difficult. Just having a flexible strip of LEDs that can stick and line the hole of the headlight surround would be just as good
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 15, 2015, 08:16:22 PM
Thought I'd update u on another little project I've been working on. A reverse camera and screen setup.

I've often thought it would be useful to have them but now I've gone for the single radio there is no way I could have a flip out screen setup as the new radio sits further forward under the hvac controls. A flip screen would hit them when it was out

Anyway,I stumbled on a photo of a highly modified 430 on the web and saw a monitor on the roll bar cover. I thought that was something different and could work so I sat in my car and imagined reversing and looking at the monitor there. It is perfect eye height

So I bought one off eBay and after many conversations and thoughts I have now mounted it. At first I was going for a hole in the cover to hides the wire but I think that is a big drastic so I have fitted it with the wire on show and coloured red. The monitor is fixed in place with black foam tape.

Hope you like it. Will give full details on how I did it laters.

Title: Re: Paul's 4thirty Build
Post by: Georgelooney on November 15, 2015, 08:25:53 PM
Another great idea Paul.. Looks great :)
Title: Re: Paul's 4thirty Build
Post by: Lee22 on November 15, 2015, 10:53:05 PM
Give it some time Paul, if it works and your happy with it, and you know your keeping it in that position, you could then drill a hole behind the screen to hide the wire.

But for now, I'd leave it as it is, until your 110% happy

Lee
Title: Re: Paul's 4thirty Build
Post by: crowley on November 16, 2015, 04:30:06 PM
If you decide to keep it there... you know what would make it look really cool  (and i dont know if its possible) but what about if it was flush mounted into that panel...
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 16, 2015, 07:42:42 PM
Lee. Good idea. Like that

Crowley. That would be the icing on the cake. It is doable but can't bring myself to cut that lovely shiny red paint. Imagine if it went wrong. Will have to see. But for builders who haven't got to paint yet I would def urge to go for it! Lol


Title: Re: Paul's 4thirty Build
Post by: Lee22 on November 16, 2015, 09:02:31 PM
Wouldn't it be goodpaul, if you could get the screen to show a red background with a chrome horse on it....
Then at the point of flicking reverse, it flips to the camera...!
Title: Re: Paul's 4thirty Build
Post by: MADMAN on November 16, 2015, 10:00:33 PM
Paul, if you cut the panel is there enough room for the roof pull handle? or another mod in mind.
I will cut it out for you no problem, but you will have to clean the fiberglass mess up after, Dust everywhere ::)
MADMAN 8) 
Title: Re: Paul's 4thirty Build
Post by: Lee22 on November 16, 2015, 10:07:05 PM
OMG Madman...  Not the angle grinder.... :o
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 16, 2015, 10:55:34 PM
Lol. Thanks for the offer Steve. Maybe one day.

Lee. Stop giving me even more ideas! But that would be good.

So I finally got round to sorting the steering wheel. Took it off the other night and is being dropped off at trimmers tomorrow. Bye bye shiny shiny.
Title: Re: Paul's 4thirty Build
Post by: MADMAN on November 17, 2015, 08:57:30 AM
OMG Madman...  Not the angle grinder.... :o

             "YUP" in various sizes ;) ;)
MADMAN 8)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 18, 2015, 09:58:39 PM
Steering wheel dropped off yesterday at 2pm. Had a chat about what I wanted doing. He's gonna try and reshape the spokes but we'll have to see. He's unpicked and removed the original already and cut out for the new one. As I wanted the new one thicker there was s worry that by removing the original it took some padding underneath with it. Luckily there wasn't anyway. So with thicker leather and maybe foam the wheel can be thicker aswell. Im going for Matt black with red stitching to match rest of the interior. Here's a picture
Title: Re: Paul's 4thirty Build
Post by: Lee22 on November 18, 2015, 10:18:07 PM
Can't wait to see the end result Paul...  ;D
Title: Re: Paul's 4thirty Build
Post by: MADMAN on November 18, 2015, 10:50:40 PM
and me
Title: Re: Paul's 4thirty Build
Post by: Lee22 on November 18, 2015, 11:26:03 PM
He may need to do a deal on another two going down Madman...!  ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 20, 2015, 06:54:17 AM
Reverse camera update. Started looking into the wiring last night to see if it all works. Managed to piggy back of the drivers reverse light live and the rear lights earth wires and it all works a treat. Nice clear picture on the screen. Put the car in reverse and after 3 seconds the screen comes on.

Worked out how I'm going to fix the camera to the rear aswell with a couple of mending plates. So at weekend should finish it all off properly. Just got to tidy the wiring up nicely. Happy days. Will put how to pictures on when it's all done.
Title: Re: Paul's 4thirty Build
Post by: MADMAN on November 20, 2015, 11:12:45 PM
He may need to do a deal on another two going down Madman...!  ;D
mines already done
MADMAN 8)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 21, 2015, 07:27:33 PM
Started on the TV camera wiring today. Thought I'd do the harder bit first and run the wires from the TV screen to the rear lights. To power both the TV and camera I am using the reverse light live.

I extended the power lead supplied with the camera with some nice thick insulated wires. I connected the red power socket and the yellow AV cable to the TV wires and then wrapped the power wire and AV wire together using amalgamation tape so it was one thick wire.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7044_zps82kgzbor.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7044_zps82kgzbor.jpg.html)


I then looked into what route to take. I decided to run the wire along the underside of the roll bar carrier and then down the inside of the b pillar area, then along the behind the cover where the drain holes are for the roof (see photo with the dotted line) then down behind the rear glove box tray and out through the hole into the engine bay. The wire has enough slack and is hidden well out of the way of the roof mechanism. I also had Little Red (Rosso Corsa) Riding Hood (My younger daughter Amelie) to help hold the wires while I wrapped them in amalgamation tape.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7048_zpsyyufndr4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7048_zpsyyufndr4.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7050_zpsho4antnt.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7050_zpsho4antnt.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7051_zpsu9emoyis.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7051_zpsu9emoyis.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7052_zpsoijawxuf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7052_zpsoijawxuf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7055_zpsr6q2i9sp.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7055_zpsr6q2i9sp.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7058_zpsvixesb8l.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7058_zpsvixesb8l.jpg.html)


The wiring near the TV screen is bulky with all the red, white and yellow connections so I zip tied this into a neat bundle and I hid this inside the roll bar carrier where the hoop attaches to. There is a lot of space here and is easy to manoeuvre in place as there is a hole where you access the bolt to attach the hoop anyway. (The white connection is not used here for the TV). In the photo you can see the bundle poking through the hole.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7047_zpsoulxxenm.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7047_zpsoulxxenm.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7061_zps9hmlwowj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7061_zps9hmlwowj.jpg.html)


In the engine bay I fed the wire inside the rear wing area and up to the light wires ready to connect.  I continued to feed the AV cable down out the back and through the rear number plate hole.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7057_zpsnap76re1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7057_zpsnap76re1.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7059_zpslxnzbtu5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7059_zpslxnzbtu5.jpg.html)


Then it was time to extend the power lead for the camera. Did the same thing: added thicker insulated wire, connected up the yellow and red connectors and then wrapped all in black tape to protect it all. I fed it back through the number pate hole and then attached the bulky taped up connection to the inside of the rear bumper via zip ties and cables trees. I then fed the wire up to rear light wire areas ready to connect it all up.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7062_zpseswwzn7u.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7062_zpseswwzn7u.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7063_zpsyj8rdeeo.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7063_zpsyj8rdeeo.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7064_zps5nydx4vb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7064_zps5nydx4vb.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7066_zpsinqbpzgx.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7066_zpsinqbpzgx.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7068_zpsanchm3ha.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7068_zpsanchm3ha.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 21, 2015, 10:11:47 PM
So the wiring is all done now

I used bullet electrical connectors to join the power and Earth wires on the TV screen and camera together and then connected to the wires that I branched off the reverse light and common on the rear lights. Taped it all up neatly and with cable ties and hid out of sight. Also zip tied the tv cable where it enters the engine bay as well neatly. Tomorrow is just doing the camera bracket. I have already sprayed the mending plates I am going to use, black. Until tomorrow.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 22, 2015, 09:27:39 AM
So as usual on a Sunday morning, I always wake up early, so while the rest of the house is still asleep I sneaked into the garage to work on the camera mounting.

The camera I got already has a bracket attached to it. The plan was to add mending plates like this so it could then be attached to the return lip on the inside of the rear bumper area, so it poked through the gap between the car and the rear diffuser. I had painted the mending plates black already. I bolted them in place and tried it out. I used dum dum to test fit it all and checked how it looked on the screen

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7087_zpsnipdmtvj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7087_zpsnipdmtvj.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7088_zpsjcrmo8eh.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7088_zpsjcrmo8eh.jpg.html)


It was working fine, but the camera could come backwards a bit more so it was more flush with the rear of the car, if that makes sense. This meant moving the camera on the mending plates up one hole. When I did this I had a lot of unnecessary metal in terms of the mending plates sticking back into the car that wasn’t necessary. Seeing as it was 7.30am I thought cutting metal and the noise it would make would be a bit out of order!

Then I had a brainwave. What if the bracket that camera came with could be switched around. I took it all apart and unscrewed the camera lens and bingo! As expected the bracket was secured to the camera by being housed between the lens and the camera body. I flipped the bracket around and now there would be no for the mending plates at all! RESULT!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7089_zps7v7g4vmr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7089_zps7v7g4vmr.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7090_zpsjr4amlbl.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7090_zpsjr4amlbl.jpg.html)


I tried it all again, and had to do a few adjustments as because I had unscrewed it all, and put it back together the camera wasn’t perfectly horizontal again. So a few goes by checking the screen and all was well. A perfectly horizontal view.

So now was to fix it in place. If you had no diffuser in place it would be easy, but for me, I had to make do with the rear number plate hole. I didn’t go straight in with the Stikaflex. I used strong double side tape, the same stuff I used to mount the TV and got the camera exactly where I wanted it. Then once happy, via the rear number plat hole, I smothered Stikaflex on top of bracket and to the fibre glass to give it extra strength. The camera weighs absolutely nothing so this should be plenty strong enough. Once dried I will tidy up the wiring a little better. Job done

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7091_zpsnydgbdg9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7091_zpsnydgbdg9.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7092_zpscfimbmdx.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7092_zpscfimbmdx.jpg.html)


After all that it was time for one of these. Happy Sunday everyone!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7093_zpsuge5xcgr_1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7093_zpsuge5xcgr_1.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 22, 2015, 05:54:50 PM
all done and working. very pleased with this mod. recommend it to anyone. I'd say total cost was no more than £30 all in. and onto the next mod. total overhaul of the headlights, but i wont start that till Dec 5th at the earliest.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 27, 2015, 07:06:47 PM
Steering wheel done. Picking it up in an hour. Fingers crossed its ok.
Title: Re: Paul's 4thirty Build
Post by: Lee22 on November 27, 2015, 08:27:25 PM
Come on Paul the suspense is killing me...!
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 27, 2015, 09:34:06 PM
Well, I have to say, my man has come up trumps again. I'm ery pleased with the end result. The rim is a little fatter than before but there is no extra padding used. It is just the result of the thicker, better quality leather used. We were going to have extra padding but their was a delay with the suppliers. It was meant to come in Tuesday but by today it still hadn't. As I really needed the wheel back tonight so I could get the car out at the weekend, I said go ahead without it. What a good descision that was. I think with the extra padding it would have looked too fat.  ;D
Title: Re: Paul's 4thirty Build
Post by: Lee22 on November 27, 2015, 11:17:10 PM
Nice, nice, nice, nice...
Love the look Paul.

Your man has done a stunning job..

I'm sure he will be getting a few more to do... Including mine   ;D
Title: Re: Paul's 4thirty Build
Post by: MADMAN on November 28, 2015, 09:35:07 AM
Yes Excellent job, well done that man.
 Put his contact details on here I think he will get lots of work from his first class job
MADMAN 8) 
Title: Re: Paul's 4thirty Build
Post by: seriph on November 28, 2015, 10:17:36 AM
Beautiful. Still would've looked brilliant slightly thicker but really looks factory and utterly yummy.
Title: Re: Paul's 4thirty Build
Post by: STRDAL360 on November 28, 2015, 12:58:18 PM
Unbelievable work!
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 28, 2015, 05:04:34 PM
Thanks for all the great comments guys. Much appreciated. So after fitting the steering wheel back, got the car out and took her for a spin before the weather turned. I must say it really adds to the driving experience. Much nice feel to it. I needed to clean the car up a bit ready for the photo shoot on Friday. It was just the wheels really, so in the end I took it to the hand car wash and got ths boys to give them a blast over with the jet wash. Just the wheels mind. Saved me a lot of time.  ;D

Then it was back home, went over the car, and clean a few bits and inside and out and now she is ready for the cat walk.

 
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 28, 2015, 05:09:15 PM
Beautiful. Still would've looked brilliant slightly thicker but really looks factory and utterly yummy.

Seriph - it's lovely to hear from you my friend! where have you been -  it's been a very long time. We've missed you! LOoks like great news for you with the 250 Cali and the Oz regulations. Looking forward to your build diary!
Title: Re: Paul's 4thirty Build
Post by: cheets on November 28, 2015, 08:52:09 PM
Nice work can not wight to see it in the  magazine  Just hope  mine  turns out as good as yours 😊
Cheets 😊
Title: Re: Paul's 4thirty Build
Post by: seriph on November 28, 2015, 09:41:10 PM
Hey Paul. Good to be back too mate. Your build has been a brilliant journey and most worthwhile. I'm sure there have been times where annoying delays, caused by the need to eat, have played a role in your timetable. Well, my work got so insanely busy that I was doing five 12 hour days then 8 on a Saturday plus a few hours on the phone on Sundays. It got to the point earlier this year that I just couldn't do it any more. The good news is that even though our family income plummeted, I have plugged my creativity back in and feel a LOT happier - isn't that the point of all this lunacy? I doubt there's a tombstone anywhere on the planet that says "wish I'd spent more time in the office"

So, though funds are depleted, I'm very much looking forward to finding a way (even though, being a Porsche fella, 'hate' BMWs) to build a replica of the mighty California. Can still recall seeing Ferris Beuller's Day Off way back when. Very happy memory, which resulted in my buying a ticket to the US to explore how I might be able to own one!

Anyway, enough of my BS! Great to see your stunning chariot mate - will look out for the magazine photos. Rock on!
Title: Re: Paul's 4thirty Build
Post by: seriph on November 28, 2015, 09:44:27 PM
By the way, I did a bit of research on building a single California over an Audi cabrio. Funny how my prejudices prevented me even considering the Beema. I've been 'schooled'

:)

Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 29, 2015, 12:55:03 PM
One of the mods I am thinking about over the winter is changing the colour of my wheels. I know I have always said that alloys should always be silver but the more I think about it, the more I think gun metal grey and red go really well. I saw this real F430 for sale on eBay and I think the grey wheel go really well. I wouldn't want to go too dark as still want so see the wheel against the tyre. What do people think? I have bought some plasti dip to try out on one wheel to see how it looks.
Title: Re: Paul's 4thirty Build
Post by: Lee22 on November 29, 2015, 08:05:17 PM
Be very careful Paul making alloys grey

1) the grey you choose normally comes out a lot darker than what you hoped
2) plastic coating is not as good as they say, ans you can't clean the wheels with any alloy cleaner if you have plastic coated the wheels
3) you need lots of plastic coat paint to paint wheels.

Just my opinion
Lee
Title: Re: Paul's 4thirty Build
Post by: Furrari on November 29, 2015, 08:30:06 PM
Going back to when I ordered my first DNA I asked for silver wheels.  Due to availability I ended up with black.  An error I'm glad was made, 'cos I think the contrast with the yellow worked well.
When I had the West Coast I asked for black wheels.  When, due to pot hole damage, I had to have the wheels refurbished I had them diamond cut.  I think the result is fantastic.
Title: Re: Paul's 4thirty Build
Post by: seriph on November 29, 2015, 09:54:36 PM
Let's face it kids, silver grey or orange would look stunning. That said, I love your wheels and love how they pop. I also appreciate the beauty of grey but for mine, it's silver for me.

Either way the chariot will look awesome.
Title: Re: Paul's 4thirty Build
Post by: Lee22 on November 29, 2015, 09:58:32 PM
Personally Paul.....

Leave them as they are..... Look amazing in silver

Lee
Title: Re: Paul's 4thirty Build
Post by: MADMAN on November 30, 2015, 09:35:29 AM
Silver Paul 8)
Title: Re: Paul's 4thirty Build
Post by: cheets on November 30, 2015, 01:51:53 PM
this is what i got from DNA but i am going to pant them :)
MARK
Title: Re: Paul's 4thirty Build
Post by: Paul79 on November 30, 2015, 07:47:59 PM
Thanks for all the advice guys. All valid points. I blame wizard as he sent that picture lol.

When I look at the grey wheels I really like them but then I look at the silver on mine and my heart says Paul don't do it. So will leave them as they are. Saves me a job. Lol.

So all that's left is the headlights to sort. I've thought of a different way to do the Angel eyes that might work. Just waiting for the bits to turn up.

Title: Re: Paul's 4thirty Build
Post by: Lord Beany on November 30, 2015, 09:22:29 PM
If my car sells before I finish the hadtop, there's always an extra job there for you! Lol.😉

The interior is really looking great Paul, excellent job.

Beany ;D
Title: Re: Paul's 4thirty Build
Post by: Ronan7051 on December 04, 2015, 03:50:02 PM
Thanks for all the advice guys. All valid points. I blame wizard as he sent that picture lol.

When I look at the grey wheels I really like them but then I look at the silver on mine and my heart says Paul don't do it. So will leave them as they are. Saves me a job. Lol.

So all that's left is the headlights to sort. I've thought of a different way to do the Angel eyes that might work. Just waiting for the bits to turn up.



Glad you decided to stay with the silver Paul, I think it looks best. The car is stunning as always by the way. What magazine shoot have you coming up? I'll have to get a copy!
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 04, 2015, 10:10:26 PM
Thanks Ronan

Magazine shoot was today. All went well. It was for complete kitcar magazine. Was very lucky with the weather today.

Car will be in 2 issues. 1st issue is out next Friday (11th)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 04, 2015, 10:32:43 PM
So now the photo shoot is done I will take the car off the road for a bit and work on improving the headlights. Will start on the drivers side first as I can do this with the car still in the garage.



Title: Re: Paul's 4thirty Build
Post by: Lee22 on December 04, 2015, 10:58:16 PM
I'll be buying that episode Paul ...

Well done mate

Lee
Title: Re: Paul's 4thirty Build
Post by: wb-in-london on December 04, 2015, 11:27:19 PM
I have an annual subscription to CKC.

Look forward to reading this issue.
Title: Re: Paul's 4thirty Build
Post by: seriph on December 05, 2015, 10:48:22 AM
What month will it be featured in? I'll try to find a copy in Oz or get one sent out.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 05, 2015, 03:20:36 PM
The January and February issues. Hopefully it will be on the cover on one of those.  ;D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 06, 2015, 06:27:58 PM
So with the car back in the garage, I have started on the headlight upgrade. As a recap I am doing the following:

1)   The LED strip lights I used originally have started to blow, so I am replacing these with better quality ones
2)   These will be DRL switch backs, so the long strip will be true DRL’s and also convert into indicators
3)   This leaves the original indicators lights defunct and not in use
4)   As the long strip used to be my side lights, I am now adding angel eyes in the main head light area and these will be my new side lights
5)   The main headlight bulbs that came with the kit are a yellow light which I don’t like so I will replace these with Xenon style ice-white bulbs
6)   I will use it as an opportunity to strengthen the whole headlight area also when it is removed


So I jacked up the car from the front, took off the wheel and arch liners and had a look. It brought back fond memories when fitting the headlights with Dad nearly 18 months ago!  ;D

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0307_zpss6jnwccn.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0307_zpss6jnwccn.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0308_zpsux09cyqs.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0308_zpsux09cyqs.jpg.html)


Headlight removed:

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0309_zpsbyru2cza.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0309_zpsbyru2cza.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0311_zps0fo3zlba.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0311_zps0fo3zlba.jpg.html)


The area I wanted to strengthen is below with the arrow. I packed it out and put more Stikaflex in place, so there was more of the headlight housing touching the metal table piece

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0310_zpsuomygabf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0310_zpsuomygabf.jpg.html)


I removed the plastic cover and put away safely for the reassembly later
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 06, 2015, 06:55:54 PM
So the new DRL’s I have are below. They have a white rubber tube that can be cut to length. I was told I could also trim the LED circuit board, but was a bit scared to. So I just stripped off the rubber tube and then bent the extra LED’s back on themselves and taped over them.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0312_zpssounxbpf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0312_zpssounxbpf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0312_zpssounxbpf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0312_zpssounxbpf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7203_zpssavpgiou.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7203_zpssavpgiou.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7204_zps0tozi5c7.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7204_zps0tozi5c7.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7205_zpszeqc7cvg.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7205_zpszeqc7cvg.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7206_zpscfindz7n.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7206_zpscfindz7n.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7207_zps9l91an6l.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7207_zps9l91an6l.jpg.html)


It is all held in place with black duck-tape.


So here are the lights in DRL form: I love them – it is a lovely ice-white solid light

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7208_zpsiegy4c3p.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7208_zpsiegy4c3p.jpg.html)


And if you connect the indicators, they go orange

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7209_zps89zfla2i.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7209_zps89zfla2i.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Georgelooney on December 06, 2015, 07:32:05 PM
They look amazing Paul
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 06, 2015, 08:02:24 PM
So I had been reading up on DRL’s and how they should work. Basically you wire them up so they come on with the ignition but when the side lights are on they should dim down slightly. On eBay you can get these automatic switches with all the wiring you need, so I have ordered one of these.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0335_zpsapeoo7b0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0335_zpsapeoo7b0.jpg.html)


So for the angel eyes  -  Daz was spot on with his measurements (thanks again) and the hole in the main headlight area is 73mm. I originally planned to mount the angel eyes inside the silver headlight area, so they would ‘float’ in the hole, but that would be quite hard to fit up in a secure manner without it looking a bit of a bodged job.

Then I found some clear covers designed to protect the angel eyes. I ordered them a while ago from China and they should turn up this week. I plan to bond these clear rings inside the silver section and then mount the angel eyes inside them. It ‘should’ work fingers crossed

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7134_zpstbcafa4t.png) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7134_zpstbcafa4t.png.html)


So here are angel eyes I have got. These ones are blue, but after chatting today with various people (thanks guys) these are not legal. So I have ordered some white ones. I had order some white ones previous but these were only 60mm, so they were too small.   But they are a lovely crisp white light as well so the 70mm ones should be good.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7217_zpskdnzvmdq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7217_zpskdnzvmdq.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7218_zpsplnjqrwi.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7218_zpsplnjqrwi.jpg.html)


Below are the blue ones just to show what I am thinking off

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7219_zpslujoqbat.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7219_zpslujoqbat.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7220_zpsg198ist4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7220_zpsg198ist4.jpg.html)

Until next time… hope you like them… 8)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 06, 2015, 10:05:19 PM
***Help please guys***

For these DRLs I need a power source that comes on with the ignition.  I thought I could run a wire from the cabin such as the radio wire but surely there must be something in front engine section. Seems a bit silly running a wire from the cabin when there's a fuse box under the bonnet. Any ideas anyone?

Cheers

Paulie
Title: Re: Paul's 4thirty Build
Post by: cheets on December 06, 2015, 10:52:49 PM
looks good bud i have put the same DRL but not connoted the indicator up at the mow i have sent you a mail mite help with the the power

i do thing it will be easer to get it from the ignition if i remember there is cable grommet near the steering column that you can use i put my park sensor cables through it and for the DRL you can cut them every 3 



Mark
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on December 06, 2015, 11:06:09 PM
Paul just been thinking on your question.
What about the windscreen wiper motor ?
Title: Re: Paul's 4thirty Build
Post by: seriph on December 07, 2015, 01:17:26 AM
bloody brilliant
Title: Re: Paul's 4thirty Build
Post by: kalifornia on December 07, 2015, 09:51:04 AM
Really good to see the modifications on the headlights. I am a bit of a DRL freak myself.

Before you fit the lights or fully assemble anything do a daylight comparison with another DRL car, you will never get the manufacturers brightness in daylight, but should give you a good idea of what it will look like in daytime driving.

I fitted some rings to my wife's BMW last year. I forgot what the company was called now, but it was recommended on a lot of forums, but was not easily found on the net.
 A lot of stuff out there is not very bright in the daytime, and tends to have a tint of blue, where you really need pure white.

Best of luck, should really look good.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 07, 2015, 07:27:42 PM
Thanks for all the input guys. Makes me feel warm inside.  ;D

Rudy. I had thought about the windscreen washer pump but I think it would only be live when the switch is operated from the cabin. But will have a proper look. That would be the easiest option by far.

I had planned to run a wire thru the grommet hole where the bonnet release cable is but it look tight and hard to get to. Cheets, will have a look tonight on the grommet by the steering column. Did u send a mail as I never got anything.

Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 07, 2015, 10:43:44 PM
Some good news (I think)

Rudy. Pls forgive me. Initially I thought you were talking about the motor for the washer jet pump not the windscreen wipers motor

I was looking around and spotted the wiper motor and saw it had a number of coloured wires going to it. I checked the wiring diagram and read the description and there was a wire that supposedly became live when the ignition was on.  A quick test with the circuit tester and yes it was the case. So we could be in business.  There is also an earth wire there so should be able just to piggy back of these.  ;D
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on December 07, 2015, 11:10:39 PM
Glad to be of some help.
Hope it works for you as the wiper motor is governed by the ignition switch.
Keep us posted and great job as always. :)
Title: Re: Paul's 4thirty Build
Post by: cheets on December 07, 2015, 11:39:20 PM
Yes bud i have tried to send it a gene let me know if you get it the net out hear is just no good lol
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 08, 2015, 11:13:58 PM
Progress. DRL wiring arrived today and tried it out with the power wire to the wiper motor. Success. DRLs come on with the ignition and also the indicators work as well. DRLs stay on and then when indicator is on it overrides them and flashes. Full write up at weekend  ;D

P.s. Cheets. Got ur email in the end. Thanks buddy.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 11, 2015, 11:42:35 AM
Magazine out today guys. Was a very nice 5 page feature on the car and the build. 56 photos! Get your copy now! Lol
Title: Re: Paul's 4thirty Build
Post by: 360MKbuild on December 11, 2015, 12:07:47 PM
Congratulations Paul, amazing :) :) :)
Title: Re: Paul's 4thirty Build
Post by: Georgelooney on December 11, 2015, 12:36:58 PM
Looking forward to reading it Paul :)
Title: Re: Paul's 4thirty Build
Post by: Lee22 on December 11, 2015, 03:21:46 PM
Unwell done Paul,

Make sure you buy a few copies mate  :)
Title: Re: Paul's 4thirty Build
Post by: MADMAN on December 11, 2015, 09:58:37 PM
nice one Paul
MADMAN 8)
Title: Re: Paul's 4thirty Build
Post by: CodeGeek on December 11, 2015, 10:06:27 PM
Should be a good read!
Title: Re: Paul's 4thirty Build
Post by: cheets on December 12, 2015, 02:36:51 AM
nice one can what to see it :)
Title: Re: Paul's 4thirty Build
Post by: Georgelooney on December 12, 2015, 08:18:39 AM
Great article & great pics Paul, looking forward to part 2, your attention to detail is incredible , can't wait to see your car at one of the shows next year :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 12, 2015, 08:27:56 AM
Thanks for all the comments guys on the magazine feature. I must have read it at least 20 times so far!!! LOL

Back to the headlights. Yesterday I put in place all the wiring for the DRLs. It was very easy.

The DRL eBay switch I got has a number of wires branching off it: To explain these in detail:
•   2 long ones for the DRLs themselves which contains
1)   A red live
2)   A black earth
3)   A blue wire that contains to the live on the MR2 side lights.
The blue wire is designed to dim the DRL’s when the side lights come on.

•   Its own live and earth wires to power the whole thing. There is an inline fuse as well on the live wire.
•   Another single white wire which I think goes to the dash lights, although I don’t think I need to use this

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7255_zpsjlvs4zzk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7255_zpsjlvs4zzk.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7253_zpsn7yyjlde.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7253_zpsn7yyjlde.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7254_zps6q0k9pm1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7254_zps6q0k9pm1.jpg.html)


So I did as planned and powered the DRL switch that I got off eBay using the power wire that is used for the wiper motor. I just used a wire branch connector and then wrapped it all up in amalgamation tape.  I didn’t bother using the earth wire here as this is not needed? How come? Well, this eBay switch is designed just to add DRL’s to your car. But I have got the switch back ones, so I have the indicators as well to think about. And because of this, the MR2 indicator wires have a live and an earth anyway. So on each side of the car I can use the indicator earth instead of the eBay one to earth the whole circuit. Each DRL switchback has 3 connectors so I am doing the following.
1)   DRL live (red wire) goes to the DRL eBay switch live (red wire) as above
2)   DRL indicator live (yellow wire) goes to the MR2 indicator live
3)   DRL earth (back wire) goes to the MR2 indicator earth

There is no need for 2 separate earth wires so this makes things simpler.

(Sorry if the above seems confusing, but it really isn’t when you see it all laid out)


I mounted the DRL switch to the bulk head just using double side tape next to the wiper motor. It will all be covered up once done by the under-bonnet cover. IF the fuse blow’s I’ll just need to remove the under-bonnet cover, but this isn’t a real big deal tbh. IF the DRL’s don’t work for a bit because of a blown fuse, it isn’t the end of the world. The indicators will still work in this instance as they have their own live power anyways.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7260_zps1chk8iev.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7260_zps1chk8iev.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7261_zpsvmfg8wfv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7261_zpsvmfg8wfv.jpg.html)


Below is the driver’s side DRL wire being fed along the back of the frunk to the right place. All zip-tied in place

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7262_zpsqt2mqq7w.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7262_zpsqt2mqq7w.jpg.html)


I also tried out some different headlight bulbs as well to see if I could improve on the ones already in there. The new ones aren’t brilliant so I have ordered some ice-white ones to see if they are any better

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7263_zpsmqhnygjs.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7263_zpsmqhnygjs.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7264_zpspxikjcwl.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7264_zpspxikjcwl.jpg.html)


I have now come to a standstill on the headlights, as I am still waiting for the clear rings to turn up to house the angel eyes. These are coming from China and expected delivery date is 7th-23rd Dec! So I might flip the car around in the garage this weekend and work on removing and preparing the passenger side to save some time! I’ve never backed the car into the garage, so wish me luck!!
Title: Re: Paul's 4thirty Build
Post by: Ronan7051 on December 16, 2015, 03:48:46 PM
Sitting in London Heathrow reading the article Paul while waiting for my last flight. Good read! Looking forward to seeing the second write up!
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 19, 2015, 08:23:09 PM
Just a quick update on the headlight project: it’s been a bit slow as I have been waiting for parts but in the end, they weren’t suitable. The white angel eyes I wanted to use, when off, look yellow – they look pretty poo tbh. I looked around for ages, but the ones on eBay all seem to be like that. I have also been waiting for the clear lenses to arrive from China. They finally did today, but again, don’t really fit as nice as I hoped.

However before they had even arrived, I hedged my bets and bought these other ones (see photo below). They are motor cycle ones with their own plastic lens. The lens fits just right in the silver cup part, which I have bonded in place now. While they are not as good as the original angel eyes I wanted to use and are not a full circle of light either, when off at least they are white and don’t look yellow. So a bit of a compromise has been taken. TBH I wish I hadn’t started this project now as it has really dragged on, but I’ve got to go for it now! A few pictures are below.
Title: Re: Paul's 4thirty Build
Post by: Lee22 on December 19, 2015, 08:42:31 PM
It will be worth it in the end mate...
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 20, 2015, 05:31:32 PM
I am pleased to report I have made some good progress today. The passenger side is all done, the car back on its wheels and switched around in the garage to its normal position.  What an awkward job that was, and it’s put me off ever building another car in a single garage. LOL

Anyway, I think they have come out pretty well. I am very pleased. Just to summarise what I have done

1)   Replaced the poor quality LED strip light I had with a better quality Daylight Running Light switch back units
2)   The DRL are proper DRL’s and come on with the ignition
3)   The DRL’s also switchable to be indicators when turned on. When off, they go back to the white strip light
4)   Added new side lights in the form of an Angel eye set up. I have bonded these in the front of the silver headlight cone
5)   Replaced the main headlight bulbs that were yellow, with brighter, white ones.

The whole angel eyes project was a bit of a saga, and many thanks for the guys’ help on here, especially Mark360, who was my agony uncle throughout the whole episode.  In the end I went for some motor bike ones that I found on eBay. They are not the brightest, but the plastic ring they came in fitted nicely in the DNA headlight cone. It’s a shame that the light is not a full ring, but beggars can’t be choosers I suppose!

What is love is the DRL’s. The light is lovely and white and crisp and much better than I had before. The original indicators are now redundant. Another good thing about the whole project as it has allowed me to redo the headlights and secure them better to the car as well. Now I’ve just got to finish the driver’s side – but they will be after Christmas I think. A few pictures are below. Hope you like them!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0513_zpsqw9igggq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0513_zpsqw9igggq.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0514_zpstclttmge.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0514_zpstclttmge.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0515_zpseckvxyyr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0515_zpseckvxyyr.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0516_zpsp8eyfmuf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0516_zpsp8eyfmuf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0517_zpsc9zkgect.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0517_zpsc9zkgect.jpg.html)

 (http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0518_zpsd0qug3ii.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0518_zpsd0qug3ii.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0520_zpsqprx5vzi.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0520_zpsqprx5vzi.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Georgelooney on December 20, 2015, 11:55:59 PM
As per usual Paul a top notch Job they look better than OEM
well done  ;D
Title: Re: Paul's 4thirty Build
Post by: seriph on December 21, 2015, 08:39:11 AM
Love them mate. The indicators are spectacular. Looks so bloody cool. Does the original have the same thing???
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 21, 2015, 04:35:56 PM
Thanks for the comments guys

No Steve, the original doesnt have those indicators nor DRL's I believe.

Other builders my want to try something different. As the original indicator is now redundant what could be done is replace the orange moon shaped lens with a clear one and make that the side light. It would look pretty cool with a nice clustered led bulbs behind it. I spoke with Brian at DNA and he said he could get the moon lenses made in clear, but it could be a while before he goes to the company to get anything made. I couldn't wait that long so went down the Angel eye route.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on December 24, 2015, 10:18:37 PM
Lee sorted these out for me. How cool are they? I loved em. Happy Christmas!
Title: Re: Paul's 4thirty Build
Post by: seriph on December 24, 2015, 10:30:37 PM
Wow. That's nit an effect I've ever seen. It's rich and subtle. I work with photoshop all the time and as a result am somewhat harder to impress than some. This is really interesting. Well done.
Title: Re: Paul's 4thirty Build
Post by: Lee22 on December 24, 2015, 11:19:10 PM
Looking good Paul, looking good... ;D

Believe it or not guys, it's a new APPLE APP.....!

Does loads of stuff, and I'm experiementing at the moment.  I'll post some more, when I've played a little

Lee
Title: Re: Paul's 4thirty Build
Post by: Furrari on December 25, 2015, 10:05:49 AM
Lee.    What's the app called please.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 03, 2016, 09:22:11 PM
So time for an update on the headlight project…

Well….. It has taken another twist! LOL Let me explain.

So the passenger light was all done and put back in place before Christmas, turned the car around and put back in the garage and attention turned to eating and drinking,  as you do over the festive period. I was waiting for another inverter to arrive anyway, and with the weather bad etc.. and me being in no particular rush I was fine with the car sitting in the garage.

Then on New Year ’s Day, when the headache had receded I started work on the drivers light. I stuck in the DRL strip with ali tape and stood back to admire my work. I had a look at the orange indicator lens and it was a bit loose, so I thought I’d take it out and re attach it better while I had the chance. BIG MISTAKE!

The mistake was that again it got me thinking about whether I could get a clear lens and make this another light of some sort. Doh! The lens is made by Valeo. A big French auto parts company. I hopped onto the computer and searched various things to see what I could find. Nothing really. I had spoked with Brian at DNA about this previously and said it was a very long shot getting them to make clear ones just as a one off.

Anyway as you know I like to use unlikely household objects on my mods I set about trying to find something that could possibly work. Some sort of clear lid. There must be something in the kitchen cupboards. At the end of the day all I needed was a clear 80mm or so clear circle of plastic, ideally with a lip/return on it. I would cut out the edge like in the orange lens to leave the moon shape.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7427_zps3jvgrxav.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7427_zps3jvgrxav.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7430_zpsao7mcta0.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7430_zpsao7mcta0.jpg.html)


So I went to Halfords, Wickes and B&Q yesterday and trawled up and down every aisle looking for anything that could work. In the end I stumbled across these. Castor covers. You put these underneath castor wheels on furniture to stop them moving around and marking floors. A bit small in diameter but they could work. No lip but for less than £1 each it was worth a shot.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7472_zpsxkvarkg1.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7472_zpsxkvarkg1.jpg.html)

I had to do the shopping on the way back and again I looked around every aisle in Tesco seeing if anything else could work. Another thing was could be a contender was the ladies make-up aisle! The powder that my better half uses – foundation/blusher etc.. Comes in nice little shallow pots – a bit like petri dishes. They were the right size, but ideally the base where the power comes in needed to be clear plastic, like the lid.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7437_zps8lbntdul.png) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7437_zps8lbntdul.png.html)


After spending 15 mins looking at the make-up and the various brands it seemed that this was a non-starter as all the bases where coloured and only the lids were clear.  Just as well really as I was getting some funny looks!   :-\
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 03, 2016, 09:46:35 PM
So today I set about trimming the castor cup to the right shape to see if it would work.

Marked out the basic shape I needed to cut out and then used the trusty powerfile to grind away the excess.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7450_zpsgwbbfdvh.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7450_zpsgwbbfdvh.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7451_zpstegukhsc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7451_zpstegukhsc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7452_zps6vyltyeg.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7452_zps6vyltyeg.jpg.html)


After about 10 mins, I got it sitting in place

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7453_zpsa0w7eukn.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7453_zpsa0w7eukn.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7454_zpsr8jhdgzg.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7454_zpsr8jhdgzg.jpg.html)


It looked ok, but then my attention turned to actually securing it. I didn’t want to just wedge it in on its own as it wouldn’t be secure enough, but bonding could be messy and would show everything as the lens is clear. Plus as it has no lip, there is a gap between the lens and the silver sprayed part on the light. Mmmmm. I thought about spraying the edge of the lens black and then bonding it. That way the black bond would be hidden under the paint. That would be one option. Again messy to do.

I did a bit of brain storming with mark360 (thanks mate)  - I tried double sided foam  - getting closer, but the stuff I had was quite thin, and then I found some draught excluder foam. Slightly thicker foam and not sticky on one side. I tape it around the lens and put in place. Bingo. Nice and secure, removable and covers the gaps.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7469_zpsviyw8gpp.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7469_zpsviyw8gpp.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7471_zpsexjbligb.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7471_zpsexjbligb.jpg.html)

So here it is in place- I am quite pleased with this

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7466_zpszirkzgun.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7466_zpszirkzgun.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7467_zps4p3tuzgr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7467_zps4p3tuzgr.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7468_zpszxo7wpij.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7468_zpszxo7wpij.jpg.html)


What I plan to do is use the indicator bulb holder but replace with a nice, bright LED bulb that looks more modern etc.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7456_zpscso8fji7.png) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7456_zpscso8fji7.png.html)


I tried it out with the normal indicator bulbs I had and things look promising  - what do we all think? LED bulbs should arrive Tues

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7459_zpsllc4niu3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7459_zpsllc4niu3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7460_zpsf1o4mizr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7460_zpsf1o4mizr.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: seriph on January 03, 2016, 10:03:11 PM
Man after my own heart. Bloody brilliant mate. I note the silver cowl next to the new clear DRL doesn't look like its cut straight but maybe it's just shadow. Of course, the only people who will ever look closely at these lights are the folks here ... AND Ferrari owners who yearn to have the same headlight setup. Not often that a copy is better than the original but I reckon you've done it mate.

Reminds me of when I built my dash-to-floor console in my 911. Nearly everyone thought is was a super rare factory item.
Title: Re: Paul's 4thirty Build
Post by: 360MKbuild on January 03, 2016, 10:41:36 PM
 ;D ;D ;D you make me laugh, when you said off out to look at makeup earlier. Looks great Paul. The lights are going to be fantastic. Will pop down to see you before my car comes back
Title: Re: Paul's 4thirty Build
Post by: MADMAN on January 03, 2016, 11:46:21 PM
And they call me bodge it and scarper ;) ;)
I love it Paul thinking outside of the box, a man after my own heart. I usually start looking at what I have got in alladins cave, if I cant find anything to bodge, I then look anywhere.
Well done, another excellent cheap upgrade
MADMAN 8)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 06, 2016, 07:07:16 PM
Quick update on new lights. Bulbs arrived and look nice inside behind the new lens. Next job is to rework the rear of the light so that when locked in place the bulb is centred. The weekends job.
Title: Re: Paul's 4thirty Build
Post by: cheets on January 06, 2016, 08:53:43 PM
Looking good Paul :)
Title: Re: Paul's 4thirty Build
Post by: MADMAN on January 06, 2016, 10:08:27 PM
how about a reflector from a cheap torch as a back?
MADMAN
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 09, 2016, 10:15:52 PM
thanks for the idea MADMAN.  ;)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 09, 2016, 10:18:19 PM
Evening all

Time for an update on the lights: I had a productive day on them today and got closer to finishing the driver’s side. The next thing I wanted to sort out was how to have the new side light LED bulb sitting more straight inside the old indicator housing. On the 430 light surround there is a circular cut out with 4 lugs at 3, 6, 9 and 12 o’clock. These enable you to lock the indicator bulb holder into the headlight housing. This is fine for the indicators but I discovered if I used the same thing with my side lights and having the clear castor cup lens, the bulbs were at an angle. They didn’t look great. I needed to find a way to straighten then up when locked in place.

I could have bond in the bulb-holder permanently so the new bulbs sat straight, but that would have been a bit silly as it would mean to change a bulb I would have to take the whole headlight out etc. so I had a think and came up with following idea. I needed to change the angle of the hole with lugs, so I needed to fabricate a new one. I needed just a circular disc with sides that I could trim accordingly and then bond on the rear so when the holder was in place it sat straighter. Guess what sprang to mind? Yes another castor cup! I bought some brown, smaller ones during the week and then had a play this morning.

I cut a hole in the middle, created the 4 lugs and tested the bulb holder. It locked in place just lovely.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7513_zpsirkb0hhc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7513_zpsirkb0hhc.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7514_zpsbx8ayvtj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7514_zpsbx8ayvtj.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7515_zpsfrfrrven.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7515_zpsfrfrrven.jpg.html)


Next I shaped the edge part of the castor cup so that when it was put in place at the rear of the light surround it straightened up the angle the bulb sat

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7517_zpshyawzbmh.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7517_zpshyawzbmh.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7518_zpsyrka1fow.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7518_zpsyrka1fow.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7519_zpsrywggpvv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7519_zpsrywggpvv.jpg.html)


As a fall back plan, if the castor cup idea didn’t work. Mark360 kindly sent down the internals of a MR2 rear light. This has 4 of the holes with 4 lugs. It turns out that none of these hole actually match up with the MR2 front indicator bulb holders so it was a bit of a non-starter. But thanks Mark for kindly sending it down superfast so I had by the weekend just in case, so not to delay the mods! i have to squeeze the mods in when i can these days!
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 09, 2016, 10:27:54 PM
So with that all working out nicely, I thought I’d better pay a bit of attention to detail. No one likes brown, so I sprayed the new castor cup black as well as the bulb holder. I put the old bulb in place to stop paint going on the metal connectors.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7526_zpstgd990g5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7526_zpstgd990g5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7527_zpshvcexiqs.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7527_zpshvcexiqs.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7528_zps3ui9egns.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7528_zps3ui9egns.jpg.html)


While that was drying I bonded in the other angel eye

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7531_zpslpmutdbe.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7531_zpslpmutdbe.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7529_zpszcmoq1e9.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7529_zpszcmoq1e9.jpg.html)


Then I bonded in the new castor cup in place. Ensuring the bulb looked straight enough and then went out for the afternoon. By the time I came back in the evening it was rock hard. I could take the bulb holder out no problems and was very pleased how it turned out. Added a bit more bond just in case to set overnight. 

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7532_zpscmdrc2vq.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7532_zpscmdrc2vq.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7533_zpsglyaqswo.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7533_zpsglyaqswo.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 09, 2016, 11:03:17 PM
Final one for tonight I promise… but it is special…

So yesterday was a special day, as the final magazine feature came out with my car in it. Sadly it wasn’t the cover story but it did make the cover (top left corner)

I was very pleased with the article and fell very proud about what I have achieved. But I couldn’t have done it without a lot of people. You all know who you are and I want to thank you all for your help. I don’t want to get emotional (I have had a few beers tonight but still….) but this forum is great and I believe it is truly essential if you want to achieve your dream and build one of these cars. It’s a great community where everyone is willing to help each other out. I have made a lot of VERY GOOD friends along the way on this journey and they will always remain my friends.

Special thanks to: Lord Beany (his diary helped me to decide to go for it), Beemaman (top painter, builder and guy), Furrari (his YELLOW 430 swung it for me and Jules to go for the convertible),  Phils99 (my build partner) Rudycob (another build partner and V6 persuader),  Tenpin & CDRSkull (great maintenance of the forum plus advice), Crossy (helped me a lot in the early days) Brian, Tony, Kelly and Roland at DNA (great people, great service, great products) MADMAN (always there for advice as he’s been there and got the tee-shirt) and then there are the people who I’ve met since the car was on the road: Lee22, Wizard, Mark360, Kal, V8 KLR, Cheets, Sir P, Paulcas) all offering advice on further mods etc.. Also from the sister site, Extreme people there have helped out a lot, JD, Alex360 and MickeyLondon

The biggest thanks got to my Dad and Jules. Love you always xxx

I’m sure there are people I have forgotten - apologies and hope to see you at Stoneleigh.

(I hope my build diary has helped a few people along the way too). Roll on the next build!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7508_zps1ev3resj.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7508_zps1ev3resj.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7522_zpstsvxpn9r.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7522_zpstsvxpn9r.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 10, 2016, 08:47:08 PM
Put back the drivers head light today. It was hard work but got there in the end. Nothing is wired up yet  - next weekends job. 

Title: Re: Paul's 4thirty Build
Post by: cheets on January 11, 2016, 12:04:31 AM
Looking good bud can not what to see the lights on :)

Mark
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 17, 2016, 05:59:17 PM
Time for an update guys.

Pleased to report the driver’s headlight is now all finished. I wired it all up during the week and tidied the wiring and put back the arch liner.  Just the passenger one to re do, but I am going to wait for the weather to get a bit better before getting the car out to remove it.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 17, 2016, 06:24:16 PM
Also started my new calliper project yesterday (thanks again for the idea Cheets) I thought about taking the car out for a drive this weekend as the weather was nice, but then the postman turned up with my dummy callipers. I had ordered some from China -  medium and large ones. The medium ones turned up a while ago, but not the big ones – but I just couldn’t wait so ordered some similar ones form the UK and they arrive within 2 days! Result! I have to say they are much better quality. All the bolts are real metal ones, whereas on the China ones, they are plastic.

Anyhow, I took the pipes off the large ones and sellotaped them together to see how it would work. My main worry was wheel clearance so I wanted the new ones to sit as close as possible to the dummy disc. While I was at it I looked at how to mount them. I thought I’d try and mount the callipers in a vertical position as opposed to at 8 o’clock as I think this looks better.  This meant drilling a hole in the DNA mounting brackets (see red arrow in picture below) and use this hole and the original hole (yellow arrow) to mount them.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7585_zpsp1qh4jcy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7585_zpsp1qh4jcy.jpg.html)

Because I am mounting them vertically, I needed to cut away some of the back of the new dummy ones so they didn’t hit the real MR2 calliper. Not much was needed, and then I drilled holes in the back where the bolts would go through.  The pictures say it all really.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7582_zpsh4kcnbyh.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7582_zpsh4kcnbyh.jpg.html)


I bonded the 2 pieces together using washers as bridging plates. These will all be painted the same colour as the calliper.  The 2 pieces will also be secured together via the Allen bolts as well for extra strength

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7583_zpscdka6nkx.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7583_zpscdka6nkx.jpg.html)



Here is it fitted in place as a trail fit. You can see the new bolt at the top. They seem pretty secure. No worse than the DNA callipers before.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7575_zps0krxy6x3.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7575_zps0krxy6x3.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7574_zpshzwsrrsi.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7574_zpshzwsrrsi.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 17, 2016, 06:32:30 PM
Tried with the wheel on – loads of room!

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7571_zpsicl6km4e.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7571_zpsicl6km4e.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7572_zps0yajrjwx.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7572_zps0yajrjwx.jpg.html)


What I don’t like it the fact there is a large gap between the calliper and the dummy discs, so I wanted to fill this with a dummy brake pad! I bought some 12mm black acrylic and made one! The plan is to bond it in place when all painted. Because there is a lip I packed out the inside of the calliper with con blocks, bonded in place. The large is not as visible with the wheel one, but still thought I’d give it a go.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7577_zps2h3cdlhl.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7577_zps2h3cdlhl.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7584_zpshwwrzw7i.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7584_zpshwwrzw7i.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7578_zpsy6cw9pzy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7578_zpsy6cw9pzy.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7579_zpsha2fsydz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7579_zpsha2fsydz.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7581_zpsp5ajuubm.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7581_zpsp5ajuubm.jpg.html)


I’ve ordered another set of dummy callipers from the UK, so when these arrive I can also make the other drivers side and then think about how to do the rears.
Title: Re: Paul's 4thirty Build
Post by: Georgelooney on January 17, 2016, 07:46:08 PM
Looks great Paul, I know how I'm doing my callipers now :)
Title: Re: Paul's 4thirty Build
Post by: cheets on January 17, 2016, 09:08:53 PM
that is ok bud glad to see its works for you the only thing i fond i have had to put some big washers to stop them flexing

for the back  i used the original DNA bracket but with a peas of aly angel up to the calliper see pic :)

as well you so much better at telling what you do :)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 18, 2016, 09:49:26 PM
Thanks Mark.

Here's a picture of the new headlights in action. (Excuse my pj's) lol

http://youtu.be/9orj4mQfQ0E
Title: Re: Paul's 4thirty Build
Post by: Furrari on January 18, 2016, 10:01:50 PM
Paul.  Could be worse, you could go wearing a onesie.   :-).
On side or running lights that looks good but with headlights on you may lose the indicators against them, but no worse than the original place.
Title: Re: Paul's 4thirty Build
Post by: cheets on January 18, 2016, 11:52:20 PM
nice job bud think i will what to get mine on the road before i have a look at this :)
Title: Re: Paul's 4thirty Build
Post by: kalifornia on January 19, 2016, 09:33:14 AM
Looking good. Can't wait to see them at Stoneliegh.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 24, 2016, 09:47:58 AM
Finished off the front callipers this weekend

During the week another set of UK ones turned up so I replicated the drivers one and built the passenger one to the same profile. I used long Allen bolts to help secure the 2 pieces together. The Allen bolts I bought, the heads were slightly bigger than the ones that came on the callipers, so they didn’t sink into the holes. After deliberation I decided to leave them sitting proud as I think this looks better and more ‘metal’ is on show.

For the brake pipes, I used the pieces that came with the callipers, cut the ends off and then used a small rubber pipe to join them together so they met in the middle.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7603_zpskf7hlwmy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7603_zpskf7hlwmy.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7604_zps808pdjtp.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7604_zps808pdjtp.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7605_zpsqu2sconk.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7605_zpsqu2sconk.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7606_zps8c4h5ym5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7606_zps8c4h5ym5.jpg.html)



I cut out another fake pad, and sprayed them in textured paint. The same paint I used on my scuttle cover. I then drilled some holes to help with the bonding into the calliper.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7608_zps4cv0pds5.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7608_zps4cv0pds5.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7609_zpshtdhphyi.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7609_zpshtdhphyi.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0951_zpsnpdkn3of.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0951_zpsnpdkn3of.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 24, 2016, 09:52:37 AM
Sprayed up the callipers next. I decided to stay with the yellow. I used the same paint as before. Enamel paint as it is tough and durable and fast drying.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7611_zpsxey6zhko.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7611_zpsxey6zhko.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7613_zps9vqdlvxy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7613_zps9vqdlvxy.jpg.html)


Once dry I coloured in the Brembo sign. In the end I just used a black permanent marker pen. Very easy to do and not messy. I had practiced on the China callipers before and it seemed to work well.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0949_zpsd1btjnyf.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0949_zpsd1btjnyf.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0950_zps3ahld9pg.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0950_zps3ahld9pg.jpg.html)


Bonded in the fake pads and left to set overnight

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0953_zpsxfxn26e4.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0953_zpsxfxn26e4.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0955_zpsrasvviho.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0955_zpsrasvviho.jpg.html)


This morning, they were dry and rock solid

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0961_zpsrk01tjqt.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0961_zpsrk01tjqt.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0962_zpsjr74hxuy.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0962_zpsjr74hxuy.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0963_zpspa6newfi.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0963_zpspa6newfi.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_0964_zpspinpclww.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_0964_zpspinpclww.jpg.html)

Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 24, 2016, 10:02:12 AM
Then, this morning I reassembled everything together. I bonded in the brake pipes and bleeds nipples from the inside as well just to be safe.  I taped up the far ends on the inside using duck-tape as well.  So now they are done

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7646_zpsk2bxmpyh.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7646_zpsk2bxmpyh.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7649_zps0uylqvht.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7649_zps0uylqvht.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_7650_zpsxshnsgot.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_7650_zpsxshnsgot.jpg.html)
Title: Re: Paul's 4thirty Build
Post by: Georgelooney on January 24, 2016, 10:16:33 AM
Very Impressive Paul, looking forward to seeing them on your car
Title: Re: Paul's 4thirty Build
Post by: cheets on January 24, 2016, 10:28:48 AM
Nice job bud :)
Title: Re: Paul's 4thirty Build
Post by: V8 KLR on January 24, 2016, 11:41:09 AM
cool.... :D
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 24, 2016, 12:32:44 PM
Fitted up and put wheel back on. Done.
Title: Re: Paul's 4thirty Build
Post by: Georgelooney on January 24, 2016, 12:43:10 PM
They look great Paul , I reckon your car is finished now.
You must have loads of spare time on your hands, I think you should finish my car off to keep you from getting bored  ;)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 26, 2016, 07:06:30 PM
Lol. Thanks George. There's always room for one more mod

Took the rear wheel off Sunday night to start on the rear calipers. Need make a new bracket but mocked it all up and ordered the bits so should be able to crack on with it at the weekend.

Title: Re: Paul's 4thirty Build
Post by: Paul79 on January 30, 2016, 04:48:53 PM
So as it is the weekend, it was onto the rear callipers. The previous weekend and during this week I had mocked up how I was going to attach them. For the rear callipers I am using the smaller ones. These came with the bigger front ones and the smaller ones are a similar size to the original DNA ones I have.

I have utilised the original holes in the DNA bracket but in order to have the callipers mounted vertically, I got some aluminium angle (40mm x 40mm) to extend it. This is bolted to the DNA bracket. Then off the aluminium angle I have 2 l-shaped brackets that then attach to the rear of the calliper.

I have built in plenty of adjustment into the whole set up, using large holes and repair washers so I can get it just right. Because the rear callipers are smaller I have had to cut slots out at the top and the bottom to allow the calliper to sit closer to the disc. The bigger front ones already had this extra slot cut out.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_1033_zpsita1nvnv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_1033_zpsita1nvnv.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_1034_zpsp3cmhh8n.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_1034_zpsp3cmhh8n.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_1035_zpsjjzyuvke.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_1035_zpsjjzyuvke.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_1036_zpsf9d78gwz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_1036_zpsf9d78gwz.jpg.html)


In place

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_1026_zps3dlxszff.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_1026_zps3dlxszff.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_1027_zpsnbfoz4pr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_1027_zpsnbfoz4pr.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_1028_zpslvqx01jm.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_1028_zpslvqx01jm.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_1029_zps1scg10z2.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_1029_zps1scg10z2.jpg.html)


I had to test the wheel clearance before I went any further. Pleased to say there is enough room.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_1032_zpsnuqs0yto.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_1032_zpsnuqs0yto.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_1031_zpsylphawwv.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_1031_zpsylphawwv.jpg.html)


I have also mocked up the fake brake pipes as well and also made a template for the fake pad

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_1041_zps775ej0r8.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_1041_zps775ej0r8.jpg.html)

Unfortunately whilst cutting out the other piece of aluminium angle for the passenger side, I had an accident and banged my index finger nail and basically ripped it almost off. Very painful so I can’t really do much else this weekend! Damn!  >:( >:( >:( >:(
Title: Re: Paul's 4thirty Build
Post by: Lee22 on January 30, 2016, 09:41:06 PM
Hope your ok mate...!

I bet you didn't swear much ;D

Looking good so far though..!  Even though the brackets do look like a 1980's meccano set  ;D
Title: Re: Paul's 4thirty Build
Post by: Furrari on January 31, 2016, 10:47:01 AM
Lees comment on the bracket is interesting.  On my West Coast we had a problem with the replica calipurrs hitting the inside of the wheels over pot holes due to the brackets flexing.  DNA redesigned the brackets and no more trouble.  These are now the standard ones.

I would never tell somebody how to build their car ( especially as DNA built mine ) but those brackets do look a bit too flexible to me.  :-)
Title: Re: Paul's 4thirty Build
Post by: MADMAN on January 31, 2016, 10:50:32 PM
Paul I think furrari is correct, I had a fake caliper hit my 360 wheel some years ago. Best thing is to make
the brackets as firm as possible
MADMAN
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 06, 2016, 09:54:33 PM
Thanks for the advice guys on the brackets. I took it on board, and doubled up the ones I was using. The whole setup is much stiffer now and no worse than using the DNA brackets.

Mocked it up for the final time during the week to test and then starting painting the callipers like before.  Once I was happy with the bracket set up I replicated the ali angle part for the passenger side. Brackets are all now painted black. I also designed a fake brake pad and cut it out of the acrylic like before. Assembled the callipers with bolts and bonded in the bleed nipples and pipes.

Finally I bonded in the fake pads to set over night and hopefully I can fit the driver’s side up tomorrow and put the wheel back on.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 06, 2016, 09:56:32 PM
More
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 06, 2016, 10:05:12 PM
So the plan is to finish the drivers side and then have a rest.  :o

I haven't driven the car since 4th December, and I know the weather is bad most of the time, but we do get the odd nice day at the weekends. I still have to fit the passenger side calipers, but the hard work has been done. Plus I need to also do the side light mod on the passenger headlight as well! But I cannot do these with the car in the garage so I am going to wait until the weather gets better and plan to do these mods with the car outside. The callipers should be a reasonably quick mod  - take car out, take wheel off and fit, Maybe one a weekend in order to keep the boss happy, but that's the way it is. I can still drive the car with DNA calipers one side and brembo's the other and I don't drive the car in the dark anyhow. Plus I should really let me finger heal

BTW thanks for all the messages, cards, flowers in response to my finger accident. Very kind!   ;D

Note to self: try and remember to wear gloves when tinkering with cars!

Title: Re: Paul's 4thirty Build
Post by: 360MKbuild on February 06, 2016, 10:17:09 PM
Still turns my stomach every time I see this finger :o

Callipers look great and very sturdy in the vid. Will be doing the same.

Title: Re: Paul's 4thirty Build
Post by: cheets on February 06, 2016, 10:45:48 PM
liking the work bud :)
Title: Re: Paul's 4thirty Build
Post by: Furrari on February 07, 2016, 09:31:05 AM
I missed it.  How did you do that finger?  Not the wife with the thumbscrews?
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 07, 2016, 12:18:09 PM
Haha. Slipped while cutting the bracket with the hand saw and my finger hit the work bench. The nail took the full force and bent upwards. A few swear words were mentioned. Lol.
Title: Re: Paul's 4thirty Build
Post by: Furrari on February 07, 2016, 12:28:09 PM
That makes certain parts of my anatomy pucker up in sympathy.  That must be so tender.
I broke my finger a couple of years ago and found the best solution was a couple of plastic ice cream spoons taped on the side kept it straight and protected it from knocks.  Another use for duct tape.
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 07, 2016, 10:18:48 PM
So I fitted up the drivers rear calliper today for the last time. Was simple enough. I took loads of photos, so I know what I did as it could be a while before I get round to the other side! LOL
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 07, 2016, 10:24:20 PM
The weather here was lovely today (not now - it's p#ssing down) So I cleaned up the garage and got the car out to have a look at them. Well, they are not perfectly vertical but okay. That's what you get for building a car in a matchbox! I made them with some adjustment so should be able to sort them, but I am very pleased how they turned out - thanks again for the idea Cheets. Did a road test - no scraping etc so all good.

Could resist and took the car for a blast. It was great - got some great reactions!
Title: Re: Paul's 4thirty Build
Post by: Lee22 on February 07, 2016, 11:40:14 PM
I think you should start taking orders Paul...!

A set in red please, with pads too....  Could I have them delivered before the end of March please...! LOL  ;D

I'm sure you can work a good price out for 'forum' friends...  ;D
Title: Re: Paul's 4thirty Build
Post by: cheets on February 08, 2016, 12:10:19 AM
Thats ok bud glad to help and looking good as well nice to to see it out of the garage :)
Title: Re: Paul's 4thirty Build
Post by: Ronan7051 on February 08, 2016, 10:20:16 AM
The beast is looking well Paul! 👍🏼👍🏼
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 14, 2016, 10:02:13 PM
Evening Guys

Just a small mod update form the weekend. Mark360 gave me this idea – to have a footplate on the passenger side like the real 360/430. He also very kindly gave me the spare footplate he had that is off a real Ferrari.  Thanks again matey.

On the real Ferrari it sits in almost a vertical position in the passenger foot well. Looking at my MR2 floor mats I decided to mount it right at the end. At this point the mat starts to curl up to an almost vertical position. Perfect.

I made 4 small holes in the mat and then used countersunk Allen bolts with nuts and washer on the other side to secure it. It needed repainting so I tried to strip the paint off with paint stripper. That didn’t really work, so in the end I just used a heat gun to heat up the paint so it bubbled and then flaked off. I primed it and painted silver with alloy wheel paint. Then just bolted to the mat and put in place.  Job done.   ;D
Title: Re: Paul's 4thirty Build
Post by: Georgelooney on February 14, 2016, 10:58:39 PM
Looks great Paul , guess I will be looking on eBay for a footplate  ;D
Title: Re: Paul's 4thirty Build
Post by: cheets on February 14, 2016, 11:14:44 PM
nice
Title: Re: Paul's 4thirty Build
Post by: seriph on February 15, 2016, 07:37:16 AM
this thing's F'n beautiful  -  is there anything of quality that anyone has put between the console and dash?

Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 15, 2016, 08:08:09 PM
this thing's F'n beautiful  -  is there anything of quality that anyone has put between the console and dash?



Not sure what u mean there seriph about the console and the dash but I'll take the f'in beautiful bit as a complement. Lol
Title: Re: Paul's 4thirty Build
Post by: seriph on February 15, 2016, 09:04:17 PM
Sorry for being unclear mate - Like G series Porsches, these vehicles don't have a dash that flows down into the centre console. I always thought that in the Porsches, this spot lacked a little finesse so I built one that housed additional gauges and switches. Thought someone might be working on a similar thing for these.
Title: Re: Paul's 4thirty Build
Post by: Lee22 on February 15, 2016, 09:53:52 PM
You mean something like this
Title: Re: Paul's 4thirty Build
Post by: Paul79 on February 15, 2016, 10:58:49 PM
Gotcha now. Yep Rudy and Wizard have that on theirs. I went the other way and removed the lower part to make it look more Ferrari like. It was certainly cheaper than the other option lol.
Title: Re: Paul's 4thirty Build
Post by: seriph on February 16, 2016, 05:00:42 AM
That pod on the top is really ... ah ... something.

;)

But yeah the bottom section is kinda what I meant. That one sits back a bit too far but it's the idea
Title: Re: Paul's 4thirty Build
Post by: CdRsKuLL on February 16, 2016, 11:23:38 PM
I've got a proper Toyota dash pod floating around somewhere.. used it when I had my DNA and installed a second screen in it.

(http://www.dnaoc.co.uk/360/pod5.jpg)

(http://www.dnaoc.co.uk/360/pod011.jpg)

No screen in it.. just the surround.  :-)
Title: Re: Paul's 4thirty Build
Post by: seriph on February 17, 2016, 07:32:49 AM
Now if it popped up and down automatically that'd be something. But how far does one have to go! :)
Title: Re: Paul's 4thirty Build
Post by: rudycob1 on February 17, 2016, 06:39:18 PM
Have a look at my build pages 29 and 38.
You will see what I did with the dash and console.
Title: Re: Paul's 4thirty Build
Post by: MADMAN on February 17, 2016, 06:57:00 PM
I've got a proper Toyota dash pod floating around somewhere.. used it when I had my DNA and installed a second screen in it.

(http://www.dnaoc.co.uk/360/pod5.jpg)

(http://www.dnaoc.co.uk/360/pod011.jpg)

No screen in it.. just the surround.  :-)
That could look pretty cool on a F430 dash, got me thinking now
MADMAN 8)
Title: Re: Paul's 4thirty Build
Post by: Paul79 on March 26, 2016, 08:11:23 AM
Well it has been a while since I posted on here. As the weather has started to cheer up and Stoneleigh just over a month away I thought I’d get a move on a fit up the other dummy callipers.

I had everything prepared and it probably took around 3 hours in total. The rears needed some adjustment to get right but it was pretty straight forward in the end. I even managed to get them sitting pretty vertical!


(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8041_zpsbqywsi4w.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8041_zpsbqywsi4w.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8042_zpsubeezxbz.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8042_zpsubeezxbz.jpg.html)


Rears

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8044_zpsddfp4kae.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8044_zpsddfp4kae.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8045_zpsnxo5innw.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8045_zpsnxo5innw.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8046_zps7t3josmr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8046_zps7t3josmr.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8048_zpsebfd05be.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8048_zpsebfd05be.jpg.html)


Fronts

Extra hole drilled in the DNA bracket to allow them to sit vertically arrowed.

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8049_zpsptuzwlgr.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8049_zpsptuzwlgr.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8043_zpsbxcrvl9v.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8043_zpsbxcrvl9v.jpg.html)

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_8052_zps80hfgzuc.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_8052_zps80hfgzuc.jpg.html)



Remember I still have to redo the passenger headlight to install the extra side light in place of the DNA indicator. I wasn’t going to bother doing this before Stoneleigh BUT as the front wheel was off I went with my heart and removed the headlight so I can get cracking on it.. 4 weeks to do it……can it be done?   Fingers crossed….
Title: Re: Paul's 4thirty Build
Post by: Lord Beany on March 26, 2016, 10:21:02 AM
Great work mate.😉

My pre-Stoneleigh checklist seems impossible at the moment, but I have to get her in tip top condition to sell.

See you there.

Beany😁
Title: Re: Paul's 4thirty Build
Post by: Alex360 on May 30, 2016, 10:28:48 AM
Hi Paul,
Well, I have just finished reading your build thread, you don't happen to work for Haynes by any chance lol?
I am greatly Impressed with the level of detail and craftsmanship during your build, and like the guys said all along, you really have earned the right to drive that beautiful piece of art.


Cheers

Alex360
Title: Re: Paul's 4thirty Build
Post by: Paul79 on June 08, 2016, 11:17:36 PM
you're welcome Alex, glad you enjoyed the read. it is rather long.  ;D