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DNA Owners => Build Threads => Topic started by: Jez on December 20, 2016, 05:28:14 PM

Title: Jeremy's 2Fifty Cal story begins....
Post by: Jez on December 20, 2016, 05:28:14 PM
Hi all, as previously mentioned I am embarking on the build of a 2Fifty California, which I ordered back in September. My donor is a Y reg 2001 2.2L Z3, with a good history and 81,000 miles on the clock, and a really crappy hood that will get replaced anyway.
After finding my donor I have spent the last month getting a few bits and bobs sorted before the strip down. I started the strip down 2 weeks ago, and this weekend the Z3 was ready for the build to start.
I collected my kit from Brian yesterday, so now the real fun begins! It's the best Christmas present ever!!!

Here's a few photos of the donor. I'll follow up with some of the stripped car ready for the kit.


Jeremy
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on December 20, 2016, 06:12:15 PM
May I offer a word of advise.  Doesn't matter at the moment but may later.   May I suggest running a bit of u section rubber around the hall edges of the holes to save possible cuts and scratches at a later date.  You can get it with glue already in the bottom of the section.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Dock Green on December 20, 2016, 06:37:40 PM
Hi, before you change the hood firm up on your colour. Red works well with some colours.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: tricky on December 20, 2016, 09:20:17 PM
great to see another build diary
take a picture of the vin plate on the front suspension,as once the kit goes on then you can't see it
I had to show the dvla photos of it to get the cars v5 changed
they might ask for it

the next big question is what colour🤔
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on December 23, 2016, 06:44:35 AM
May I offer a word of advise.  Doesn't matter at the moment but may later.   May I suggest running a bit of u section rubber around the hall edges of the holes to save possible cuts and scratches at a later date.  You can get it with glue already in the bottom of the section.


Great advice! Keen to know a brand of material that has the glue in the channel. Thanks
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on December 23, 2016, 03:41:07 PM
Seriph.
I've looked for the supplier I had my trim from but it was a long time ago but there is a good selection on eBay as rubber trim.  Some will grip the panel without glue.
Sorry mate.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on December 23, 2016, 05:15:20 PM
Seriph.  Try " Metal House". They do sone that, although not glued, look as though it will stick in place.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on December 23, 2016, 08:17:30 PM
Thanks. I have access to regular channel but the glues variety would definitely be superior.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Paul79 on December 29, 2016, 08:33:53 AM
welcome. looking forward to this build  ;D
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on December 29, 2016, 11:19:39 PM
Just a wee bit of inspiration :)


(https://s-media-cache-ak0.pinimg.com/736x/32/4d/8f/324d8fbd54c46f1a968f1de22fec7938.jpg) (http://supercars.net.s3.amazonaws.com/blog/wp-content/uploads/2016/04/24133444/1103437-1024.jpg)
(http://www.conceptcarz.com/images/Ferrari/Ferrari-250GT_SWB_3119GT_RM_Monterey-02.jpg) (http://www.cargeek.co.nz/wp-content/uploads/2015/01/Ferrari-250-GT-SWB-California-Spider.jpg)
(http://www.egmcartech.com/wp-content/uploads/2015/02/2015-Baillon-Collection-1961-Ferrari-250-GT-California-Spyder-11.jpg)(http://images.carpictures.com/media_12_full/12H6352402776712.jpeg)
(https://s-media-cache-ak0.pinimg.com/originals/47/df/bf/47dfbf6a632239dda4f6eee3c263649c.jpg)(http://www.blogcdn.com/www.autoblog.com/media/2010/07/1961ferrari250gtdsc1331.jpg)
(http://www.auto.dvdrwinfo.net/images/good-1961-ferrari-250-gt-california-9-ferrari-250-gt-swb-california-spyder-1024-x-768.jpg)(https://s-media-cache-ak0.pinimg.com/originals/78/93/5e/78935e760ea902a8c30b17ea56517a38.jpg)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on December 29, 2016, 11:29:30 PM
BTW I know that last one isn't a Cali but thought to include it to see what red carpet looks like .... mine will have dark grey or black I think, as I intending driving it .... a LOT! The tailored and buttoned-on rubber mats make sense to me
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 03, 2017, 10:42:54 AM
Thanks Tricky, Dock and and Seriph for you advice and comments.  Here's a few photos of progress so far, and a little background history.
36 years ago (1980) at the age of 20 I built my first ever kit car, which was a Burlington SS replica of a Morgan, based on a Triumph Herald. This picture was on the day my Dad and I collected the kit. We managed to load it all onto the roof of my Dad's car and transport it all the way from Leamington Spa to Leeds without losing any of it! 5 years later I built my second kit car - a Ford Capri based JBA Javelin.
After all this time, I have itchy spanners again, so I am now embarking on the third kit car build of the trilogy, and just before Xmas my Dad and I collected the new kit from Redditch. This time the kit was loaded into a hired van. I don't think we'd get away with loading up the roof rack these days!
In both pictures, we have my Dad chatting to the company owners (Hadyn Davies, and Brian), my kit loaded up in the background, and the car I will be building in the foreground. I just love the 'time travel' depicted in these photos. This was the first time my Dad had seen the 2Fifty in the flesh - and I think he approves looking at his reaction!
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 03, 2017, 10:50:01 AM
Making good progress over the Xmas break. Woke up Xmas morning to find my wife and son had decorated my body kit, and even fitted the seats!
The Z3 has been totally stripped, cut and all DNA brackets fitted. I took the opportunity to service the electric windows which were a bit slow and clunky. The plastic guides were worn so I replaced these (£6 on E-Bay) and thoroughly cleaned and re-greased all the tracks. Windows now glide up and down as expected!
Started to trim the body this weekend. This was a little bit daunting as some of the scribe lines are hard to see, so I decided to draw where I thought they were, and then check with Brian before cutting. Hopefully if we have dry weather I'll get this completed next weekend since I have to do this in the garden.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on January 03, 2017, 11:27:52 AM
Wonderful. Hope to learn a bunch :)))))

Great work on the windows.
Aussie cars suffer a bit from that issue, due to the heat and dusty conditions. Hopefully the repair on the one I get will be as straightforward.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on January 03, 2017, 05:13:04 PM
I always liked the Burlington, I built a Domino Pimlico for my wife in 87, she loved it....it was always supposed to be a practice for something more exotic for me....but time passes....still back on the spanners now.

I can't say I was a fan of the Jav....but looks like you made a good job of it, despite the aesthetics being, what shall we say....an acquired taste  ;)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 04, 2017, 09:40:39 AM
Sir Percival, I have to agree with you! My favorite of the two was indeed the Burlington, but at the time I built the Javelin I was really attracted to the concept of a four seat convertible - in the 80's this was not a common sight! I always thought the Javelin looked reasonable from the rear, but I really did not like the front end at all.
The nice thing today is that there is absolutely nothing I don't like about the 2Fifty Cal - it is a beautiful car from every viewpoint.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on January 04, 2017, 02:42:56 PM
Well said mate  ;D
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 31, 2017, 12:34:30 PM
Well I have spent the last 3 weekends trimming the body kit and additional panels. Had to do this outside on the back lawn as it creates so much dust. The whole garden looked like it had a dusting of frost until we had some rain!
Anyway, most trimming is now done, with the exception of the bumpers that I still need to finish off. One tip for anybody else - when trimming the rear of the boot section, leave the return edge on as this works nicely and gives a much larger surface to Bond onto the bodywork. You just need to flair this away in the corners.
I am now dry fitting all the bodywork, and making small adjustments where necessary to get the best fit possible. This is time consuming - you end up putting the body on and taking it off at least 10 times, and needing another helper for this means I had to drag my lovely wife out many times!
Once I have adjusted and checked the fit of all panels, I'll then remove them all, and then etch back and prime all bonding areas on the metalwork and GRP.
Also had a battle with the exhaust adapter supplied by DNA. On my 2.2 the distance between the pipes on the car was 2mm less than the adapter, and the flange on the adapter was not quite large enough to slide onto the pipes. I spent two hours one Saturday fighting with it before giving up. After a lot of measuring, and making templates I went back to see Brian, and we hot-footed off to his supplier for a bit of tweaking. They widened the flange and also opened up the distance between the two pipes. Glad to say that it’s now fitted snugly, and they have the new measurements for future manufacturing. Adapter is now fitted, but the exhaust is removed again until after painting.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on January 31, 2017, 01:03:17 PM
This is dead useful Jez....I got DNA to fit the body on mine but, if I do another, I would like to do it myself and save a few bob...so watching with keen interest.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 31, 2017, 05:44:56 PM
This photo shows how leaving the horizontal bit on the back of the boot lip provides a nice flat bonding area on the metalwork. You just need to sand it down quite thin.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 31, 2017, 05:49:43 PM
I also found that I needed to remove a little of the corner of the metalwork on the Z3 wing, as the GRP was just resting on this corner. Taking an angle grinder to this part allowed it to sit nicely onto the body either side of the boot.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on February 14, 2017, 02:40:38 PM
Does anybody know what colour this is? I like it.

Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on February 14, 2017, 04:54:54 PM
Jez, have a look through this;

http://www.ferrari-collection.net/color/ferrari_colors.htm

Looks like Blu Sera to me.....but I am colour blind so you need to have a look yourself.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Rippin6Gears on February 14, 2017, 05:01:41 PM
Probably Blu Chiaro
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Dock Green on February 15, 2017, 06:46:30 PM
Good choice & I get a chance to inspect the colour before it goes on the Daytona  ;D
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Dock Green on February 15, 2017, 06:52:04 PM
As this
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: OXO on February 15, 2017, 06:56:15 PM
What a super project ! Thanks for sharing.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on March 21, 2017, 02:44:26 PM
Well its been over a month now since I last posted, so an update is due.
I have now got the rear section bonded on, the front section bonded on at the A pillars, and the boot lid all fitted and working, with the solenoid fitted and tested. Cabling this up will wait until after paint, so it has the customary temporary boot release cord at the moment.
I also assembled the wiper system, and after a bit of messing around with fitting, that is now completed, wired up and tested before bonding on the front section to the A pillars.
I decided to take a chance on fitting a stubby antenna replacement for the radio, so I remounted the amplifier at a 45 degree angle pointing backwards. The 10 cm antenna (£5 from Amazon) screwed on replacing the original one, and this all fits nicely underneath the GRP rear wing.
Early testing indicated the reception was at least as good as, if not better than the original antenna, so I am very pleased with this neat, hidden approach.
I had cut the body in the filler hatch to the shape shown on the scribe marks, but after fitting the hinge and leaving it screwed on for a few weeks, when I removed it I saw some cracking of the fibreglass around the holes. I decided this would be a weak point (probably not much glass fibres in this area?) so I cut it all out, and made a metal plate to bolt the hinge to. This plate was then bonded in place behind the hatch.I'm now happy with that.

Had a few trips to DNA to see Brian and the boys - always fills me with enthusiasm when I see the near completed cars they are working on!
And I got to see the progress on Dock's new project - looking good.

Unfortunately I am away on business for two weeks, so not much more will happen until April, but when I get back, I'll be fitting the bonnet, then finally bonding in the rest of the front section.
Then I will turn my attention to bonding on the door skins and then fitting the bumpers and nose/screen trim surrounds before its ready for paint.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on March 21, 2017, 03:02:58 PM
Antenna solution
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on March 21, 2017, 07:14:12 PM
Looking really good Jez. The antenna solution very clever. Good progress, well done mate.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on June 12, 2017, 09:25:52 PM
Quick update.
Been juggling lots of business travel with working on the 250 Cal and doing the normal household jobs, so progress has slowed down a little. However, the bodywork is all complete, bumpers trimmed, windscreen trim also cut to fit, all lights, handles (except boot) grills etc trial fitted and removed.
Door pulleys now fitted and door handles pre-fitted and removed.
Also made a start on the interior, so now the inside is a complete mess with no dashboard, seats, centre console etc. I have cut out the Z3 dash ready to join to the DNA dash moulding. Also had the angle grinder at the metalwork so the new dash can be fitted.
Spent this weekend cutting out the headlight covers and bezels from the acrylic moulding supplied by Brian. Time consuming work, and unfinished due to the death of my Dremel mid cutting!!! New one arrives tomorrow so will finish that next weekend.
Car going for paint at the end of June  :D
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on June 13, 2017, 01:12:58 AM
Thanks for the updates! I imagine you don't have progress pics as they're one more step in a million actual steps that get the car done!

The dash sounds an interesting process - keen to know how straightforward you're finding it.

Thanks again

Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on June 13, 2017, 09:40:36 PM
A few pictures from the last 2 months.......
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on June 13, 2017, 09:42:58 PM
and more.....
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on June 14, 2017, 12:30:20 PM
Looking great Jez....the dashboard pictures will be a big help to me. I have bought a second hand black dash (as mine is beige) so I can cut it before I need to fit it. This will save me having to paint the beige one black, and leave the car drivable for longer, while I prep it separately.

Looks like the light surrounds are coming on...when I was at that stage I started using the little dremel rolled emery tools....they shift it OK if you don't let it get too hot, and give a nice rounded edge to the interior corners where the tabs stick out for the bolts.

What colour have you decided on?
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on June 14, 2017, 08:35:24 PM
I see your 'specs on the scuttle panel.  Do you ever loose them?  I used to loose mine but then I put coloured pipe cleaners around the arms. ( any bright colour). No more problems.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on July 06, 2017, 04:31:26 PM
Not lost them yet Furrari (well not for more than a few minutes anyway!).

July 5 Update.

Headlight covers and bezels now ready, and all the fun and games completed with the side grills. Boy were they a challenge! Trimming them to the exact correct thickness and getting a good fit was tricky. Then cutting the slots at the correct angle without damaging them - you only get one shot at this!
Had to do a bit of body filling to reduce the curve of the cut out for the grills. It seems the radius is not quite right so you end up with a gap. I bonded a small piece of left over fibreglass to the back of the wing, then filled the corner with good old P38 filler (last time I used that stuff was in the 80's filling rusty parts on most of my cars!). Then I re-cut the corners to the correct radius and sanded them back flush ready for the paint shop.
Anyway, all good and these parts now ready to go off for prep before chroming.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on July 06, 2017, 04:37:54 PM
Last little job was to trim the windscreen trim that goes along the bottom. I was not happy with the corners where they meet the windscreen pillars, so lots of filler and re-shaping was carried out.
I also made a couple of adjustments to the bonnet fit (I was not 100% happy) and the filler flap. Trimmed the bumpers a bit more so they looked a better fit, and bonded some spacers onto the front grill surround that will get chromed. This makes it sit centrally in the aperture.

Car is now ready for collection on Monday, when it goes off to the paint shop. Still can't decide on the colour yet though......
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on July 06, 2017, 04:42:34 PM
So for colour I am thinking red, but not Rosso Corsa. I rather like the Rosso Rubino which is a little darker and more of a ruby red (Rubino).

Closest colours I have found are Ford Ruby Red or Jaguar Italian Racing Red. The alternative colour was a dark blue like Blu Scuro........

Any suggestions?
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on July 06, 2017, 07:29:29 PM
If you are considering a darker red, how about Brandy Wine.
Not period but looks damn good in sunlight.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on July 06, 2017, 08:22:59 PM
Your chariot is looking great! Have you considered grey? It's the colour of the only RHD 250 ever made.

Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on July 06, 2017, 08:24:53 PM
https://youtu.be/IDe5xaMtcTc
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on July 10, 2017, 10:17:14 AM
Well after a little over 6 months off she goes to the paint shop......
Several weeks now to tidy up the garage a bit, sell off all the Z3 bits I don't need, and start work on the interior panels and radiator grill. And cut the grass (neglected gardening duties in favour of playing in the garage!).
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on July 10, 2017, 07:43:15 PM
Hope it goes well mate....get that grass cut...it will take your mind off it!!
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Steve4321 on July 10, 2017, 08:11:52 PM
 :D6 months, very well done. All the good stuff to do now.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on July 21, 2017, 01:21:57 PM
OK I have just 2 days to decide on the colour...... ::) :o :-\
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on July 21, 2017, 03:19:19 PM
Deep royal blue enamel with camel trim:)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: johnjames on October 03, 2017, 03:13:55 PM
Thanks Jez for sending me a picture of your car at the paint shop really like the colour that was my second choice but in the end I decided to do my white, anyway looking forward to meeting you at Stoneleigh or before take care John James
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: kalifornia on October 03, 2017, 06:38:17 PM
Trust me, stick to Red, as it is meant to be. I am sure Furrari will be dipping his awe soon.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on October 04, 2017, 08:24:11 AM
Kal.  Go and wash your mouth out.   Red indeed, what are you thinking.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on October 04, 2017, 11:49:57 AM
Ivory looks spectacular :) wine red interior would be a beautiful inclusion.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: MADMAN on October 04, 2017, 12:45:06 PM
Trust me, stick to Red, as it is meant to be. I am sure Furrari will be dipping his awe soon.
               Yup Kal youre right red with light tan interior thats what mine will be.
With a garage full of Rosso Corsa 322 why would I paint it any other colour ;) ;)
MADMAN 8)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on October 12, 2017, 12:36:23 PM
Well its been a while since I posted any 'progress reports' but that is mainly because there was very little progress over the summer. Stuck in the queue for paint behind John James, but now I'm glad to say it's completed!!

Here's a few photos of the painting process.....

Colour is Rosso Barchetta (312) so now you know!

Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on October 12, 2017, 12:38:03 PM
And a few more with the final colour.....
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on October 12, 2017, 01:00:02 PM
Oh mama! That's gonna be one sweet ride.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on October 12, 2017, 01:10:43 PM
The car is being collected on Monday - can't wait! I've only seen the photos of it so far......
Hope its as good as it looks......
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on October 13, 2017, 11:22:02 AM
Jez.  Can't wait?  Like the rest of us you will have to.  It's like Christmas and your birthday when you were little.  How big is the smile on your face.?
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on October 13, 2017, 11:41:05 AM
 :D :D :D :D :D :D :D

That big!
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on December 21, 2017, 02:38:01 PM
OK I have just fitted the stainless bumpers to my 2Fifty and there is a lot of interest in how they fit, so here's how I did it.

First I protected the area around the bumper mount hole with tape so I did not scratch the bodywork when repeatedly mounting the bumpers.
I started by placing the trimmed grp bumpers onto the metal bumper frame and then slid the stainless bumpers over the grp.
The first thing you need to do is remove a section from each end of the bumper so that the stainless ones slide over the straight part.
Then you need to cut back the grp bumpers so they are flush with the inside edge of the metal frame.
Pushing the stainless bumpers over the top, you can then see more areas where trimming would be needed to allow them to come closer to the bodywork and so you cannot see any of the grp once fitted.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on December 21, 2017, 02:41:56 PM
On the front bumper I ended up cutting the grp ends off in line with the ends of the metal bumper frame. I then made sure the grp was mounted centrally, and bonded it to the frame using PU adhesive.
On the rear bumper I found I had to remove the back part of the grp bumper to allow the stainless bumper to slide over enough.
At first I was only cutting out the areas where the number plate lights and reversing light / fog lights bolt on to allow clearance.
In the end I decided this whole section of grp was not required, but I left it on until after I had bonded the grp bumper to the frame, to make sure both sides of the grp were in exactly the same plane.  I only bonded the area around the mounting tubes, and did not bond the middle section.
After the bond had set, I then removed the middle section of grp so I had no problems with clearance for attaching the lights. The result was just two grp mounting points over which the stainless bumper just slides on.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on December 21, 2017, 02:44:10 PM
Once the grp bumpers (or what was left of them) were bonded, I then prepared the grp, primed all bonding areas on both parts, then I was ready to bond the stainless onto the grp. I did this with the frame and GRP mounted on the car so I could get everything centralized and make sure the gaps were even all around close to the bodywork.
The rear bumper was easy to bond this way. Just make sure the sides are level and not sloping up or down.
The front was slightly more difficult as it tends to drop down at the sides, making the gap too large. So for this one I centralized the position and marked up the grp and stainless so I could then bond this ‘off the car’. This enabled me to wedge the stainless bumper against the grp so that it bonded with the sides being perfectly level, and not dropping down.
Once bonded they just fit like the grp ones do. The only thing I need to do is paint all the insides matt black so it looks nicer (not that anybody can really see behind, but I know it would just finish them off properly) and fit some support mountings to either side of the rear bumper, because this is quite a long section and should be supported.
Result is some very nicely fitting stainless bumpers (with a few grubby finger marks I need to clean up!)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: johnjames on December 21, 2017, 03:18:08 PM
Looking really good Jez I'm very impressed I wish I had known about stainless steel bumpers earlier I waited 6 months for mine to be sprayed I will see how they go and if they don't work out I will change them four stainless steel ones keep up the good work looking forward to seeing more pictures have a great Christmas John James   ;D  8)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on December 21, 2017, 07:41:17 PM
Very impressive and useful...looks fairly straightforward.

Couple of questions;

You say you primed the GRP (obviously I will have to sand off the "chrome" on mine first) can you say exactly what primer (brand/type/quantity) you used.

And secondly the glue you used to glue the stainless bumpers to the GRP....again brand etc.

Thanks mate....looks like I need to go for the ones without brackets....I would have a nightmare trying to cut the supports out of the GRP.

Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on December 21, 2017, 08:15:33 PM
Hi  Perce,

Brian supplied PU adhesive and a primer to use when bonding the body to the Z3. The adhesive is Techniflex PU adhesive and the primer is Techniprime, both supplied by Albert Jagger in Walsall.
https://www.albert-jagger.co.uk/

They only had grey or white, not black last week when I bought some more. But grey works just as well.

You rough up the surfaces to be bonded with sandpaper, then clean off any dust and give the surfaces a coat of the primer. Once dry (a few hours or overnight if cold) you can then bond the parts using the PU adhesive. It cures with moisture from the air, and after a few hours or overnight it will be bonded. Sticky gue....

Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: firefife on December 21, 2017, 11:14:51 PM
They look great Jez,
 Just a couple of questions
1  On the front GRP ones, is it just the ends cut off or does the centre come out as well?
2  How did you do the support on the sides of the rear one?

A bit of fettling there but really worth it
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on December 21, 2017, 11:34:11 PM
On the front bumper I only cut off the ends, and trimmed the grp back to the frame on the inside edge.
i have not yet made the supports for the rear bumpers sides. I plan to bond in some 3 mm plates into the stainless bumper cavity, then I will mark up and drill holes in the bodywork. Then I can mark up where the bolts will line up on the plates, and can then drill and tap these to accept the bolts. The bolts will have rubber sleeves so you won't see any metal.

That's the plan.....

Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: firefife on December 22, 2017, 09:26:56 AM
Sounds like a good plan to me Jez, I think that is the way to go. It was my thoughts that just bonding on the bar would eventually sag.
I posted an email reply that I got from Christoph from Harringtons re brackets, etc on the stainless bumpers post
Ian
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on December 22, 2017, 09:50:35 PM
Jez, Does the stainless rear bumper have the bolts holes for the fog and reverse lights already drilled?
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on December 22, 2017, 10:46:27 PM
Yes Perce,  it only the rear bumper has the required holes. None in the front bumper.
Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on December 25, 2017, 12:08:38 PM
Have a great Christmas everyone.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on December 29, 2017, 11:26:35 PM
Just thought I'd share this with you....

https://www.facebook.com/GentlemenDriversASD/videos/1535305716561515/

Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: johnjames on December 30, 2017, 09:55:49 AM
Hi Jez
That clip is from the classic car show on Channel 5 series 1 episode 1, which is Jodie Kidd in a 250 California films at Portmeirion a resort near penrhyndeudraeth in north Wales where the series of The Prisoner was made it is one of my favourite Car moments I have it on my phone,. John James
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on January 01, 2018, 10:02:19 AM
It's a real shame that DNA no longer produce the 250.  It deprives so many people the pleasure of seeing such a beautiful car.

Oh, anne a happy Hogswatch to any Terry Pratchet fans out there.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: tenpin on January 01, 2018, 10:18:13 AM
...
 a happy Hogswatch to any Terry Pratchet fans out there.

In those circumstances I believe the appropriate response in character is:

THANK YOU
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: firefife on January 01, 2018, 12:06:34 PM
Ditto
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: johnjames on January 01, 2018, 12:28:45 PM
Have a great one.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: firefife on January 14, 2018, 04:57:52 PM
Hi Jez,
I phoned Albert Jagger asking about Techniflex PU adhesive and Techniprime primer,  Spoke to a guy who told me the minimum order for posting was £50 before VAT & for collection was £25. I only need 1 'sausage' & one primer & cost was around £23 + VAT + £10 p&p.
Spoke to a second (lady this time) & she says that as I don't have an account it would cost around £53 +VAT. Bit of a difference here & too far for me to travel there to pick up. She also said she would check with the first guy I spoke to with regards to price difference & one of them would phone back - that never happened.
Any ideas of another brand good enough to use, I only need it for the bumpers which you don't need to come adrift & fall off?
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 14, 2018, 06:15:06 PM
That's very odd. When I called in there before Xmas I bought 3 cartridges ( not sausages ) of grey Techniflex, and the total cost was under £9 for three. I thought that was cheap at the time, but did not query it.
I did notice a big sign on the sales counter saying 'minimum order £25' but maybe I was just lucky.

I have used some Puraflex 40 from Toolstation and at first I thought it was not so good. It seems to take ages to go off (4 or 5 days, not 24 hours like Techniflex) put now that it's hardened, it seems just as good. It was 'secure but soft' after a day or so, but did take 5 days to become like Techniflex does after 1 day.

https://www.toolstation.com/shop/p67949?searchstr=Puraflex

I suppose your need to decide if you can leave the items you are bonding for an extended period of time. When bonding the bumpers be very careful to somehow hold them in the correct position, as this adhesive tends to push the parts apart while it's setting.

Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 14, 2018, 06:18:41 PM
Alternatively, I have been recommended this stuff available on Amazon although I have not used it myself. It was recommended by another 250 builder.

https://www.amazon.co.uk/Tiger-Polyurethane-Adhesive-Sealent-310ml/dp/B002SQY852/ref=sr_1_1?ie=UTF8&qid=1515953818&sr=8-1&keywords=Tiger+pu+adhesive

Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: firefife on January 14, 2018, 08:40:37 PM
Thanks for your reply Jez, very strange the differences in prices.
I have used the Tiger before & seems quite good but don't know how it will withstand the weight of stainless bumpers. Not tried the Toolstation one before & can do the five days bit, how to hold everything square whilst it is going off would need some thinking about. Used to use Wurth which was excellent but not seen that in a while.
The other problem is getting hold of a decent primer as that seems to be a key to the bonding process.
You have been very helpful, thank you
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: jaguartvr on January 14, 2018, 09:06:40 PM
Slightly different idea.

I had to have a panel sealed in a leaky Corsa, common problem and I used someone who specialises in this problem.
He bonds the panel in with windscreen glue, takes an hour to set but as he said, once it is on the only way it will come of is if you cut it off.
The secret to a good bond is that it must be cleaned and primed.
Full kit on eBay £11

https://www.ebay.co.uk/itm/WINDSCREEN-GLASS-SEALANT-BONDING-ADHESIVE-GLUE-CAR/370240015556?epid=1188171113&hash=item5634064cc4:g:RpYAAOSwimdXpElg

To hold a windscreen in for years it must be strong.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: firefife on January 14, 2018, 09:56:26 PM
Thank you Steve, I will look into that
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 14, 2018, 10:42:53 PM
Thanks for your reply Jez, very strange the differences in prices.
I have used the Tiger before & seems quite good but don't know how it will withstand the weight of stainless bumpers. Not tried the Toolstation one before & can do the five days bit, how to hold everything square whilst it is going off would need some thinking about. Used to use Wurth which was excellent but not seen that in a while.
The other problem is getting hold of a decent primer as that seems to be a key to the bonding process.
You have been very helpful, thank you

I would not worry about the weight of the bumpers. Once you have cut back the grp bumpers so the stainless ones fit over, they sit quite nicely without any adhesive. So there's no weight working against it, but you just need the adhesive to bond them permanently.

Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: firefife on January 14, 2018, 11:06:36 PM
Thanks again Jez, lots of good hints & advice always welcome. Still haven't received the bumpers yet
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 23, 2018, 01:12:21 PM
Update on my build progress.
Finished almost all the re-wiring and fitting of new switch gear. Cables run through bulkhead for new sensors (still need to fit sensors though). Fitted resistor to fuel sender. Fitted all door mechanisms and electric window switches, cut and drilled door and window winder shafts ready to fit door cards.
Dashboard - I trimmed the dashboard and door cards to the trim lines that were scribed on them, and have trial fitted and adjusted many times. Both the dash and door cards had large gaps that I was not happy about, so I have spent a lot of time building up those areas and re-shaping to get a better fit. In particular the corners of the dash where they meet the A posts, and the rear and front ends of the door cards.
Now sanded, filled, primed, sanded, re-primed and re-filled the dash and the door cards. Final coat will be satin black before then using VHT Crinkle Plus (not really happy with the yellow colour!)

Hopefully I'll get those parts crinkled this week, then will leave them to cure for a couple of weeks before fitting the dash and the rest of the interior trim.

Started the seats - removed and cut one subframe, ready for assembly onto new DNA supplied seats.

Still unsure bout what to do for the side vents, front grill surround chrome parts...... Has anybody found a good Hydro-Chroming service?

 
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 23, 2018, 01:15:05 PM
Primed dashboard ready for black satin coat, then VHT
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on January 23, 2018, 01:46:14 PM
Jez.  I asked about  hydrochromeing when I had my diffuser done.  Nobody seems to do it like they do carbon fibre dip.  There is a place in Basildon who do chroming on plastic (same as Wayne did).  I have used them but I wasn’t happy with the work and got my money back.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on January 23, 2018, 08:47:26 PM
Nice work Jez....I quite like the funky yellow!
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 23, 2018, 08:56:57 PM
Shall I leave it that colour?
Do you think it goes with Rosso Barchetta??

Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on January 23, 2018, 11:46:46 PM
No, you are right........you will just have to re-paint the car.....Mick would like that.    ;D
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 24, 2018, 02:42:17 PM
Just thought I'd check before I go wrinkle black.

It is kinda growing on me - I might keep it this way. It would be the only 250 Cal with a yellow dashboard  ;D
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: johnjames on January 24, 2018, 03:53:53 PM
High Jez it would certainly be different when I sprayed my dash I also done the top of the doors and the bits on the steering column and the glove box lid trying to get the texture to look the same is very hard.  
If you did spray it yellow   👓  would you have yellow anywhere else in the car like piping on your seats also would you have it on the top of the doors. You can always try it with a couple of spray cans and then see what you think.
 but if I was you I would ask the boss (your wife) and see what she says. Anyway good luck all the best John James. 8).  8)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: jaguartvr on January 24, 2018, 05:34:08 PM
How about a good flocking?

https://www.ebay.co.uk/itm/Flocking-service-have-your-dash-door-cards-interior-exterior-parts-flocked/322712887738?hash=item4b232fe1ba:g:A1IAAOSwU9xURCUu
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on January 24, 2018, 05:40:29 PM
A YELLOW car yes.  A red car with a yellow dash.  No, clashes.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 24, 2018, 06:02:39 PM
Noddy car comes to mind.....Red and yellow together!! ;D ;D ;D
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on January 24, 2018, 07:14:55 PM
Is that you driving Noddy's car.... :D
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on January 24, 2018, 08:52:56 PM
I stand corrected, but only if you have blue tyres.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: johnjames on January 24, 2018, 11:26:07 PM
I think it would look really good with a spare wheel on the back and of course you must wear a blue hat with a bell on the end I can't wait to see what comes up next. But also I like the idea have a good flogging now that could be quite interesting.   John James
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: johnjames on January 25, 2018, 06:57:51 PM
Hi Jez I've got the nardi steering wheel and when I ordered my kit from Brian I asked him where to get the steering wheel and the boss and bought them on eBay the same as Ian I have to drill and tap it. I have posted pictures on my build of the steering wheel.  John James
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 26, 2018, 09:14:30 AM
Does your boss look like this one? It's a common one on EBay.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on January 26, 2018, 10:29:27 AM
I used the OMP boss and a spacer from Europa spares on top of it.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: jaguartvr on January 26, 2018, 10:30:03 AM
There are 2 steering wheel bosses available on eBay, one is £29 and one is £83. I bought the cheaper one being a skinflint, it does fit if you use a hammer, you also need a grinder. The indicators won't cancel and it feels as if it sticks when using it.
I then bought the £83 version. Fits perfectly and the slip ring fits neatly inside. Indicators self cancel.
Don't waste your money on the cheap one.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 26, 2018, 10:55:42 AM
Thanks for the recommendation. I have looked on EBay and can't seem to find anything at £83.

Do you remember who sells it?

Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: jaguartvr on January 26, 2018, 12:09:34 PM
Here you go, its the OMP one

http://www.ebay.co.uk/itm/OMP-STEERING-WHEEL-HUB-BOSS-KIT-fits-BMW-Z3-95-02-OD-1960BM545A/352081213485?epid=1649886296&hash=item51f9acf82d:g:fEQAAOSwPh5ZOBdc
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 26, 2018, 01:39:54 PM
Thanks all for your help. Ordered today.

Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on January 29, 2018, 07:24:57 AM
Continuing the Noddy theme.....
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: johnjames on January 29, 2018, 11:22:05 AM
I like it at least it's different don't forget the spare wheel on the back can't wait to see you in your Noddy hat with the little 🔔  keep up the good work John James.  ;D.   ;D
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on January 29, 2018, 02:32:14 PM
That’s a sort of baby bird beak yellow, so if you see an adult bird feeding it worms you know why.   :-)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on January 29, 2018, 03:05:27 PM
Once, when in Decimomanu, the bombing range in Sardinia, we had a baby owl roost in the jet pipe of one of our Buccaneer's. No amount of banging or shouting would get it out and the first sortie of the day was fast approaching.

So I climbed in and started up the engine....it didn't come out until I hit max throttle....out came the owl in a ball of flame, and travelled about 200 yards like a meteorite....I always felt bad about that....but it did look spectacular, poor thing...and it managed to set some scrub on fire as a last act of defiance!

Moral is; don't let an owl nest in your car....it is not good for conservation.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on March 16, 2018, 10:18:59 AM
Hi all you 250 California builders. Does anybody know what size (thread size and length) screws are required for the steering column cowl? I did not get any with mine.
Brian though it was M4 but that's too big. I then tried the electrical socket screws you get in your plug sockets, and they are also too big.
Any ideas?
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: jaguartvr on March 16, 2018, 10:25:53 AM
Electrical socket screws are 3.5 so I would suggest you try 3mm
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on March 16, 2018, 02:14:36 PM
Jez

I used M3 dome heads, 6mm long....they are still a bit long but I fitted a couple of small fibre washers.

As the bolts are so small it is imperative to line up the holes/threads very accurately, or cross threading is easy to happen.

I got mine here...if you cut and paste it into e-bay;

M3 M4 M5 M6 M8 A2 STAINLESS STEEL SOCKET BUTTON / DOME HEAD ALLEN SCREW BOLTS
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on March 16, 2018, 02:55:58 PM
Thanks guys. On order....
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on March 20, 2018, 06:23:27 PM
For those 2Fifty owners who need to fit new senders for water temp, I did mine today. It was very easy. Locating the spare plug was the first task. It's quite obvious when you get underneath and look under the exhaust manifold from the front.

I found that I was able to unscrew the plug, and keep my finger in the hole until I screwed in the sensor. I only lost a 1/4 cup of coolant  :D.
Just be aware the plug and the new sensor are different sizes so make sure you have both size spanners with you before you unscrew it.

Then I found a way of making sure the cable does not go anywhere near the hot exhaust, so I routed it through some old rigid plastic tubing I had lying around.

All good.

Then I tested a few of my electrical connections, including the fuel gauge. I remember when I removed the old fuel gauge back in October it was reading just under 1/4 full. The new gauge is reading 1/2 full, so either I've gained some fuel, or something's not quite right.  >:( I have fitted the resistor.......

Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on March 20, 2018, 07:32:45 PM
Jez, it does say in the blurb that comes with the gauges, that the fuel gauge should be accurate at full, and accurate at empty, but between the two it might not be.

Checking accurate full will be easy enough......but you would have to be brave to run it to empty though.

Sounds like regular top ups at the petrol station will be a requirement   :(
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on March 20, 2018, 09:07:38 PM
No fuel gauges are accurate at any other times because of the complex shape of fuel tanks
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: firefife on March 21, 2018, 09:28:34 AM
Thanks Jeremy, have copied for reference ;)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on March 21, 2018, 08:50:17 PM
Got both oil temp and oil pressure senders installed today. More difficult than the water sender just because of tight space, but got there in the end.  :) :)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on March 21, 2018, 10:00:37 PM
Well done mate, I am on leave starting Friday, so these are my jobs for next week. Fitted the passenger door car, looks nice.....but the door will not shut properly.

Investigated and found that the door seal is worn out, the metal grippers have given up, allowing it to twist when in position thus stopping the door from closing because the balloon seal is higher on the door side than it should be.

Honestly.....there is always something!!!!!!!!!
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on March 22, 2018, 08:11:26 AM
That's a shame. I also have a damaged door seal. Trouble is, I have searched on line for months and they just don't seem to be available anymore. I have also looked at alternatives, but the profile they use is very unique.

I think the only chance is a breakers yard and hoping the one pulled off is in better condition....
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: firefife on March 22, 2018, 09:24:32 AM
My 'small' gauges came without senders or instructions. Phoned Brian & he has organised them to be sent here. They said that they always check before dispatch -  but they definitely weren't in there. Brian has had to pay £60 for new ones so I will have to reimburse him for those.
As you say, always something.  :-\
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on April 07, 2018, 01:22:57 PM
Well I've been making good progress over the last few weeks, got all the dash in and all working, and carpets etc. However yesterday I found none of my instruments worked (fuel gauge, rev counter, oil pressure etc.) Checked the 12 volt supply to the instruments and it was only showing 3 volts.

Had another look today and now it's dead, no volts at all. I hate electrics.......

Off to a wedding today so no time to investigate further, but if you have any suggestions I'd appreciate them.

Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on April 07, 2018, 02:31:02 PM
There can be many faults that cause low voltage.  Being silly, the first is the battery and it’s conections,  the second is the earth connections.  Then it’s just a case of checking the voltage at each point to Earth.   If the car has been standing for a long time then you can get corrosion at the joints.

If you don’t like BMW sparky things you should try Merc sparky things.  Defies all logic, even my weird type.

Even if a battery is showing 12v it may be faulty and won’t give any current but this shouldn’t be the case if there is no load on it.

Have fun and don’t pull your hair out.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on April 09, 2018, 11:50:58 AM
Fixed your electrics yet?
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on April 09, 2018, 12:18:46 PM
No. At the moment I moved on to something else as I was getting very frustrated with it. So the car is up on axle stands while I change the springs. Got the rears done OK but I've taken the front struts to a local garage to swap the springs. I kind of like my face the way it is so did not fancy playing with spring compressors. I took them in this morning, they will be ready by end of day.

Once the car is back on terra-firma I'll be happy climbing inside again to remove the dashboard (again!). Then I can start the fault finding to trace the problem.....

Just ordered my tyres and getting them delivered to the same garage. Dropping my shiny wheels off with them when I pick up my struts, so I'll have them back by the weekend.

Hopefully on track for MOT in two weeks, and if I have time, a trip to get a new hood before Stoneleigh. If not, Ill just have to come with the ropy old one and get that done later.

Chromed items *should* be ready on Wednesday (after their second attempt as the first time they did a crap job) so I will have those bits to fit over the next couple of weeks too.
Seat frames and plastic trim all sorted and ready to fit. Carpets in, so should not be too much of an ask to be ready for the show. Just hope the MOT tester is kind...
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on April 09, 2018, 01:30:02 PM
Don't blame you with the springs....I had two sets of spring compressors fitted and it still scared me. PITA about the electrics. I'm sure it will sail the MOT....shiny wheels always help.

I'm still having difficulties with the door cards impinging on the bottom door seals and stopping the doors from shutting nicely...got the passenger side sorted but I'm on the drivers side now....it doesn't help that they are well warped as well.

Instruments in, dash almost finished....trying to work out a way of using the old key as an immobiliser...I shall follow your guide for fitting the new bumpers.

P
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on April 09, 2018, 01:57:41 PM
I'll send you some photos later of my immobiliser solution...Just got a conf call for the next hour.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on April 09, 2018, 03:10:26 PM
I bought a new key from Fleebay, transferred my electronics and chip into it. I mounted the EWS antenna ring behind the dash, between the boot release and hood switch, but lower down in line with the hazard switch. Inside the cavity of the ring, I created a foam 'trap' that grips the key when inserted. This was made with two pieces of 6mm self adhesive foam, one stuck on top of the other to create a 12mm thick foam section bonded to the back of the dash. This has a slit cut into it with a craft knife.

The hole I cut is rectangular - the same profile as the metal on the uncut key. So I can insert the BMW key into the rectangular hole, and the metal part goes into the foam slit, which grips it.

Then I can use the DNA ignition key to fire it up. Works a treat.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on April 12, 2018, 06:06:58 PM
Fault tracing in the spaghetti behind the dashboard  :( :(
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on April 12, 2018, 06:12:27 PM
Fun, fun, fun.

It may be hard to trace faults but I see you have lables the wires.  Always a good start.


Best of luck,  and when you finish yours, as an experienced man you can play with my wiring.

See one, do one, teach one.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on April 12, 2018, 06:49:25 PM
It's not fun at all! Two fuses have blown, hence no power to instruments and clock. However, there's no point in replacing the fuses until I figure out why they blew, otherwise it might just happen again.

The good news is that checking back to the BMW wiring before I spliced in the power is good (once new fuses are in) so whatever it is, it's down to my wiring. I'm never convinced that crimping connectors is always good, even though I do a 'pull test' on the wire after crimping.....

I'll get there in the end. I have to, the car must be ready for Stoneleigh!!

Once the dash is back in ( for good I hope) then the centre tunnel trim goes in, seats in, rear panel fixing, then it's on to the shiny chrome bits on the outside. At least the springs are done which was not a job I was looking forward to, so the rest is all plain sailing.......oh, and a new hood needs sorting too.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on April 12, 2018, 08:37:42 PM
You have my sympathy.

As you know the majority of my splices were done using solder butt connectors....however I did a few on the instrument cluster that were necessarily spades, male and female bullets, and a few ring connectors.

One of those was on the clock earth. Not only that but I linked all the other earths, from all the other central instruments, to it. To start with they were all dead. Got to work with the multi-meter and it was the short length of earth wire from the clock. The crimps looked perfectly sound and were made with an expensive, and very good, ratchet crimping tool...the problem was that the crimp had been made just back from the bare wire, on the insulation.

It even passed the "pull" check. Whilst trying to figure out why I could not get continuity along this bit of wire, with what looked like perfectly good crimps...suddenly the ring connector to the clock just dropped off...and the wire was broken clean through the insulation...so just behind the bared wire.

The bad crimp had severed it.

The moral is this; you can't see if a crimp is good, you can only test for it...and it is possible that somewhere you have what looks and feels like a good crimp ...but it may not be.

Hope you find the gremlin soon.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on April 13, 2018, 06:16:26 PM
It’s always a debate, do I crimp or do I solder?    I prefer to join wires in what is called a modified lines' mans joint. ( basically each wire is wrapped around other, then soldered) with heat shrink on.  If I’m doing a crimp type joint I like to use uninsulated crimps, solder them and again use heat shrink.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on April 13, 2018, 07:04:56 PM
Well I've been through all the connections and checked and rechecked each and every one. Some I have replaced and it re-routed the way the wires run to avoid trapping any.
All instruments now working again BUT now the left hand side lights front and back don't work. Checked the fuses and guess what? The fuse for that circuit has blown.   >:( >:(

I am just wondering if my repeated disconnecting and connecting of the negative battery terminal is causing these 17 year old fuses to pop? I have noticed the indicators occasionally flash as I connect the terminal, and you do get the odd spark when connecting.

Ordered a BIG box of fuses from Amazon.......
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on April 15, 2018, 08:40:27 AM
Finally getting somewhere! After a day spent rewiring and rerouting cables, then a couple of hours messing with the tachometer, I hope the dash is now finally installed!

Just waiting for the instrument pod to come back from chroming then I can fit all the small gauges - but all tested and working now. Should get that sometime this week.

Today I'll fit the steering column switches ( also tested and working) then I can final fit the rear bulkhead and thread the seat belts through the guides, then seats in and that will complete the interior.

Then I have all the shiny bits to fit on the outside and I also need to tweak the bonnet and boot alignment as they were not quite right after painting.

And the sun is coming out next week too!!  ;D :) :)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on April 15, 2018, 09:10:38 AM
Absolutely spectacular mate well done. Can’t wait to see more.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on April 15, 2018, 09:23:17 PM
Looking great Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on April 19, 2018, 09:08:11 PM
Just about completed the interior, all that's left to do is the instrument pod, steering wheel and seats. Chrome has let me down and failed to deliver, so can't do all the trim outside. Still, I can book an MOT for next week ( they don't need chrome!!)

Tentatively booked the replacement hood for week before Stoneleigh. Just need those shiny bits to arrive!!
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: jaguartvr on April 20, 2018, 08:21:19 AM
If you are stuck on the chrome, i use a company that does vacuum chrome plating. They can plate plastic or GRP. Because it is vacuum plated there is a maximum size they can plate. What you are plating needs to be perfr=ect or the defects will show through. Best to have the item painted in gloss black before plating, that will show up any defects. It is meant to last longer than the chrome spraying which can turn yellow/blue with age.

I had my front grill apperture plated, looks good but not perfect but that was down to my lack pf prep, I didn't have it painted first. Costs around £120 for my grill.
If you need any details please drop me a PM
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on April 20, 2018, 10:37:19 AM
Jag.

I had my head light surrounds chrome sprayed by a company in Basildon.  It was a disaster.
DNA were good enough to give me another set.  I had them vacuum deposition chromed by Dual Plating in Tysley, Birmingham.   What a difference.  Absolutely brilliant.  Not cheap but very well done.  I can recommend them.

Just one point.  You do need to spray them with a UV resistant lacquer or it will yellow. ( remember it’s aluminium not chrome).
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: jaguartvr on April 20, 2018, 06:05:36 PM
http://www.vmclimited.co.uk


They are geared up for production runs, I pop in with parts and some crispy £ notes. I don't know if they will do mail order car parts, you could always call them and see.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on April 21, 2018, 08:36:50 AM
Thanks for your suggestions. I got the parts back yesterday. I am reasonable happy with the windscreen trim and front grill surround, but the headlight bezels are badly done and these are a focal point on the car and very visible. One is ok, the other is naff. The side grills are not perfect but the imperfection is on the underside you would not see unless you are on your back looking up.
Worst thing is after chasing them for over 4 weeks they've now 'lost' the boot handle. I was on the phone to them yesterday and they are still trying to find it.

I know I can get the headlight bezels and side vents in polished stainless steel so I think that might be the way forward, when I have more funds,but for now I'll have to use the grp bits if I'm going to finish for Stoneleigh.

I hope they find my boot handle soon. So frustrating.....
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on April 21, 2018, 10:53:06 AM
That's sort of a good/bad news mixture....hope everything works out.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on April 21, 2018, 07:02:59 PM
Had some success today. Instruments finally in, and grill and spots all fitted.

 :) :)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on April 24, 2018, 07:01:16 AM
Well the bad news is that after two days of searching the Chromers cannot find my boot handle. It turns out that after I rejected their first attempt at chroming the parts, they sent them all off to another chromer because they wanted a better quality job doing. Somewhere between the two my boot handle has gone missing.

So now I have a dilemma. I have found a source for a genuine Ferrari 250 boot lock and handle at an extortionate price, but given the trouble I've had getting the 3D printed one chromed this might be an option. Only problem is a 5 week lead time, so not going to be ready for Stoneleigh. Do I get an MGB GT boot lock for now, or just turn up with a hole in the boot....?
 >:( >:( :(
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: beemaman on April 24, 2018, 08:39:59 AM
Hi
I might have a boot handle off Dna 250 at work ile have a look when I get in  see if can find it
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: beemaman on April 24, 2018, 10:03:05 AM
If any good I’ve got one here in primer I’ve had lying around ??
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on April 24, 2018, 10:13:04 AM
That would be very much appreciated. I have asked Brian to see if Another can be made but if you have a spare one that would solve the problem.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: beemaman on April 24, 2018, 10:31:19 AM
Hi
Yes I’ve told Brian I have a couple of them here as they were his I had to chrome with some other parts so he will contact you soon
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on April 24, 2018, 10:48:28 AM
Wayne I would like to buy one of those as a spare if I could....mine has dropped off a couple of times and sustained some damage....any chance?
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: beemaman on April 24, 2018, 11:15:56 AM
Hi Percy call Brian I have 2 of his here I’m sure he will let you have one  :)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: beemaman on April 26, 2018, 11:09:27 AM
Jez just posted next day signed for so should get it tomorow sometime.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on April 26, 2018, 11:24:50 AM
Cheers Wayne. Much appreciated.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on April 26, 2018, 06:44:41 PM
Wayne, spoke to Brian today, he says I can have the other one....can you hang on to it for me and I will collect as soon as I can?

Thanks matey.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: beemaman on April 26, 2018, 08:48:38 PM
Hi
Yes buddy no probs ile keep it here til you pick it up :)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on April 27, 2018, 11:38:14 AM
Had an appointment with the man from the Ministry of Transport this morning. He gave my 250 a thorough checking and declared that it was absolutely fine, and a lovely car!

While I was there I noticed a rather nice 1930's Bentley tucked away in a corner of the workshop. "Ah! That belongs to Mr Davies, he was just admiring your car!" explained the mechanic.

I thought that was a nice compliment.... A good day! On-line to tax it now (might wait until Tuesday though).

Engine seems a bit lumpy and under-powered, but it has not really been driven for 18 months, and the mechanic said 18 month old fuel will not help. I'll fill it with premium gasoline once it's taxed, then see if it improves.

Just have to finish off the chrome side grills, windscreen trim and headlights - and boot handle but this will not be ready before Stoneleigh as I still have to get it chromed. Thanks to Wayne for posting it to me - should arrive today.

Also booked in next week to replace the tatty red hood with a nice new black one......... :) :) :) :) :) :)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on April 27, 2018, 12:57:36 PM
Well done Jez.......another milestone chalked up.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: johnjames on April 27, 2018, 07:41:58 PM
Hi Jez car looks good just realised your registration number BPR 737A. My registration is BPR 745A. We must have bought them about the same time looking forward to seeing you at Stoneleigh John James.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on April 28, 2018, 08:13:31 AM
Yes, I bought mine registration in November 2016 before I started work on my z3.
I was happy that the MOT tester was not concerned about me having black and white plates, even though they are not legal. Top guy, he gets it. I did have the yellow and white ones in the boot just in case though....
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: johnjames on April 28, 2018, 05:11:50 PM
Hi Jez I have been driving my with the white number plate on the front which I think it suits the car and the Black and silver one on the back if I undo the screws on the back number plate the yellow one is underneath.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on May 02, 2018, 07:02:04 PM
Final push to finish in time for the weekend. Its tight, I am not going t be able to get the headlight bezels and covers fitted - I don't want to rush that. Need to fabricate some brackets.
Yesterday I got all the chrome trim fitted around the windscreen. Looks so much better.

Spent last night bonding mesh onto the side vents, and today bonding side vents into the bodywork.

Booked in for a new hood on Friday.......and still waiting for my boot handle to come back from the chroming company. Guess that will be Saturday's job.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: MADMAN on May 02, 2018, 08:20:06 PM
Looks First Class Jez
MADMAN
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: johnjames on May 03, 2018, 02:10:16 AM
Looks nice in red Jez looking forward to meeting you at Stoneleigh. Are you going for a red or black roof ? John James
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on May 03, 2018, 06:34:53 AM
Black roof John.

See you Sunday!
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: firefife on May 04, 2018, 10:09:05 AM
Looking great Jeremy, I won't have the headlamp covers fitted either, still waiting (a year now) for my stainless ones to be finished & unfortunately my ones with the kit is with the guy for a pattern.
My hood is booked to be fitted next week so will have the tatty old one on for Stoneleigh.
Having problems with Speedo setting (Error keeps showing) - thank goodness for Sat navs with speed reading, tacho (not working at all but gives a pulse when ignition is turned on) & fuel gauge goes straight up to full & stays there :(
Looking forward to meeting you all at Stoneleigh
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on May 04, 2018, 09:20:36 PM
We can chat through all these issues on Sunday. See you all then.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on May 04, 2018, 09:23:00 PM
PS.
It's amazing what you can do with BlueTack!

Just driven from Crawley to York with head lamp domes and bezels attached with just BlueTack!!
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: firefife on May 07, 2018, 08:43:19 PM
Was hoping to have a chat with you & meeting you Jeremy, but I didn't see you whenever I went on your stand.
Maybe next time mate
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on May 08, 2018, 09:42:13 AM
Yes I think we must have crossed over. There was only 1 hour when I was not there at the DNA stand - and I went over to the Italian Replica Club area during that time!

Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: firefife on May 08, 2018, 10:06:33 AM
Lol, sods law. Was on IRC stand most  of the time except for wandering over to your club & doing some tool shopping inside halls (that was very sparse this year too)
Shame I couldn't have finished mine properly before the show, but it was good enough. Still not got my stainless headlight cover rims made, hopefully he will have them finished for Tatton Park in 3 weeks time. He has only been doing them for a year
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on May 09, 2018, 07:50:55 AM
Popped around to my local garage yesterday and Mr Davies was there again with his Bentley. Very nice machine.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on May 14, 2018, 05:25:10 PM
Hi all,

I've had a letter from my insurance company requesting that I have the car valued by an 'independent valuer'.

Has anybody else had to do this? If so. who do you go to for the valuation? I have 7 days to respond or my car will self destruct......
Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on May 14, 2018, 07:23:09 PM
Not me mate....mines on with Flux with a fixed 45k right-off deal....they just asked how much I thought it was worth.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on May 31, 2018, 04:38:28 PM
Finally got my agreed value sorted with Footman James. Very please that the additional premium lifting the value was only £26.
So total cost £286 fully comp, with agreed value of £80,000.

Many thanks to Madman for helping me out.

 ;) ;) :D :D
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: MADMAN on June 01, 2018, 08:43:12 AM
Your welcome Jez,
Aditional £26 nice one. Give me a shout next year if you need form sorting again
MADMAN 8)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on June 03, 2018, 09:58:11 PM
My daughter took some really nice photos of me and my 250 California last weekend.

https://www.facebook.com/jeremy.hinchley/posts/10156244762537348

She did a really good job capturing the beautiful lines of the car......

Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on June 04, 2018, 12:38:30 AM
Stunning. Only see two on your page and that’s just cruel ;)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on June 07, 2018, 11:45:41 AM
OK I've copied the photos so here they are.

I have been having so much fun driving this car. The acceleration is awesome and the exhaust sounds terrific. Long live the summer!

Jez
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on June 07, 2018, 06:42:14 PM
Who's the ugly bloke leaning on your lovely car?   ;D
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on June 07, 2018, 07:29:54 PM
 :D :D :D
Cheeky!
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on June 08, 2018, 12:08:07 AM
Look at thatbsmooooooth bastard DARING to lean on that breathtaking £10,000,000 beauty!

Must be such an incredible delight to own.

Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on June 08, 2018, 12:09:32 AM
Definitely worthy of throwing some cash at a specialist photographer I reckon. It’s such a WOW result.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on June 18, 2018, 05:50:24 PM
So chuffed this weekend!
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: MADMAN on June 18, 2018, 08:03:06 PM
Well done Jez, but as I said to you, I expecred you to get car of the show
MADMAN
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on June 21, 2018, 11:05:03 AM
Well that's weird!!!

It was such a gorgeous night last night with a beautiful sunset, so I decided to go out for a top down drive in the dusk.

First time I have ever driven the car at night, so its the first time I've used the lights. Set off down the road and oncoming cars were flashing me. It turns out that my dipped headlights and full beam are reversed, so when I have the dipped lights on, its full beam, and when I switch to full beam it turns on the dipped lights (plus full beam)!

I must have screwed up the wiring. Just checking it today and my 'labels' are correct in that I labelled the main beam/dipped beam on the Z3 when I disconnected them.

I followed Percy's lead when he figured out the wires on the new headlights.....

"Finally got the headlight wiring sorted;

The Red wire from the supplied headlight unit is the sidelight and connects to one wire on the Z3 sidelight

The black wire and the blue/white wire attach to the Z3 dip headlight wiring

The blue wire connects to one of the wires on the Z3 halogen headlight"

Except there was one minor difference. I have Blue/white, Black, Red and Blue/Red. So I am guessing my lights are wired differently to Percy's (possibly a different supplier/make?) and so perhaps my Blue/White is actually the main beam, and the Blue/Red is the dipped.

I'm going to swap them over and see what happens.

I guess I will have to get my lights re-aligned because they were obviously set up with full beam on rather than dipped.

Hey-ho, the joys of car building.......
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Sir Percival on June 21, 2018, 12:20:28 PM
I can only agree....try swopping them over....mine were a real pain, but got there in the end by trying different combinations.

I'm surprised they didn't mention anything about it on the MOT?
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: firefife on June 21, 2018, 01:07:02 PM
Had the same happen to me driving back from Tatton Park, everyone flashing me. When I got home I put the beams against the garage doors & they were reversed.
If the dipped lights were on then they were full beam, put on full beam & dip comes on - but with full beam.
I left last weekend's show early to beat the dark & had side lights on before we got home. I tried holding the flash on with just the side lights & no one flashed so wires are connected wrong. Thought it was just me but seeing two others makes sense that new lights wire colours are wrong, will be looking at it on Monday, a couple of other jobs to sort by the end of next week before we go to Le Mans.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on June 21, 2018, 01:17:48 PM
I swapped them over and it seems to be correct now.

I can only agree....try swopping them over....mine were a real pain, but got there in the end by trying different combinations.

I'm surprised they didn't mention anything about it on the MOT?


I am too. I have been looking on-line to see if the lights are aligned on dipped beam or full. No-one mentions it, so I assume it is dipped. If that's the case, then my lights are probably adjusted to point too low........I will pop down to my local garage and get them re-checked.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on June 23, 2018, 04:36:48 PM
Went back to my local garage that did the MOT to get the headlights re-aligned. Told him that I'd screwed up the wiring on the headlights. He said 'yes I figured that out so I adjusted for the dipped beam anyway, but I forgot to tell you about it!'
Anyway, we checked them again and just had to tweak them slightly.
All good now. 😉
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on June 23, 2018, 08:12:44 PM
Headlights are usually aligned with dip beam set to 1/2 to 1 degree down.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on June 23, 2018, 08:16:50 PM
Maybe. But you still need some references to adjust them to.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on August 15, 2018, 12:09:33 PM
I finally decided to tackle the headlamp bezels and get rid of the crappy plastic chrome ones That have been on all summer. I had bought a set of polished stainless steel ones back in April, but because they were a difficult thing to fit I decided to wait.
The plastic chrome ones are already starting to fall apart, so I thought long and hard about how to fit the stainless ones. Many sleepless nights thinking about the best way to fit.
First I decided I did not like the black rubber edge trim that was supplied, so I sourced some translucent silicone edge trim, which is claimed to be non-yellowing, so I thought that might look better. Easy to replace every couple of years if necessary.
Next I looked at the supplied brackets, and decided that they were too big and visible once the stainless bezels were fitted, so they needed to be reshaped and much smaller. I also looked at the genuine Ferrari 250 and noticed that the bezel mounts are painted in body colour (as they are part of the bodywork) so I thought, that’s what I will do too.
The supplied bezels are supposed to be fitted with self-tapping screws into the brackets, but I did not like that idea either, so I wanted to use dome head machine screws. This means I need a threaded M5 bracket, but the brackets were only 1mm thick, so cannot be tapped.
So I thought I would ‘JB Weld’ some M5 flange nuts under the brackets so I could screw the dome heads in.
So after all these decisions I started to trial fit the stainless bezels to the shape so I could work out where to fix the brackets. The stainless MUST have the protective edge rubber on when you do this, because there’s a high risk of damaging paint with the sharp edges of the stainless. The bezels needed quite a lot of bending and ‘stretching’ (I know you can’t really stretch stainless, but it feels like you are doing) to get them to the right curvature, and even then they are close but not perfect.
Once that was done I could mark where the brackets should go before drilling the bodywork for them. Measured and re-measured this 4 times, just to be sure.
Then I very carefully drilled the holes for the brackets (that took a lot of courage taking a drill to my shiny bodywork!!) and then fitted the brackets. All were flat and full size at this time. Next I removed each bracket, and bent it slightly to match the curvature of the Perspex and bezel so that there was only a 5mm gap between the stainless and the bracket. Once I was happy with all the bends, I then held the stainless bezel in place and marked where the holes needed to be on the brackets. I was very careful that the bezel was in exactly the right place all around before marking any hole points.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on August 15, 2018, 12:13:52 PM
Then the brackets came off again, and the holes were punched and drilled. I was using M5 screws so I drilled a slightly larger hole in the bracket (5.5mm) so that it would be easier to line up the nuts.
Once all the holes were drilled I refitted the brackets again, then I fastened the bezel in place with the screws and flange nuts to check for fit. When I was happy with that I then marked the brackets with how much to trim off so they would not be visible under the bezel tabs. I shaped the brackets into little ‘plectrum’ shapes, so that they got narrower towards the inside of the dome, and would not stick out anywhere beyond the bezel tabs.
Once I was happy with the shape, I refitted the brackets and test fitted the bezels again. Happy with that, I then set about ‘welding’ the flange nuts under the bracket hole with JB Weld. I cleaned up the brackets and the nuts before applying the epoxy glue.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on August 15, 2018, 12:18:29 PM
I let the glue set overnight, then I cleaned them all up again and set about painting them, first with two coats of etch primer, followed by four coats of body paint (I got a spray can off the internet colour matched to my car Rosso Barchetta 312).
Once all the brackets were nicely painted and dry (three days later) I fitted them back on the car.
Then I took the Perspex domes and offered them up to the light aperture. Of course they would not fit as they did before because the brackets were there now, so I had to trim a little out where each bracket sits. Then the holes did not line up exactly, so they were enlarged a little to make them line up (the stainless bezels and original plastic bezels are not exactly the same).
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on August 15, 2018, 12:25:34 PM
I may be teaching my Grandmother to suck eggs here but here’s a bit of advise when fitting headlight bezels.

We usually drill a clearance hole for the screw thread and then a countersink/bevel to take the head of the screw.  This gives a sharp angle where the countersink and the clearance hole meet.   Unfortunately the corresponding screw will rerely have a corresponding sharp corner.  To save risking cracking the Perspex just round of the corner of the hole so it clears the screw.

I’ve not cracked a cover ( there is still time) but I have seen it done so I was able to do it when I was fitting covers to my GTM.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on August 15, 2018, 12:29:17 PM
I decided to seal the edge where the plastic domes touch the bodywork with some kind of rubber
seal, in the hope that it would prevent 90% of water ingress. I thought about various options from P
seal, flat seal, to finally deciding on E profile seal since this had tiny raised sections that would
compress easier than the P section.
I had to trim more off the edges of the domes all around so that it still covered the light aperture but
left a gap all around that the stainless bezel and edge seal would fill.
Once I had trimmed enough off, I placed the domes back on, and marked where the edge was, then
removed them and stuck the seal on all around so that the very edge of the dome would sit within
the width of the E seal.
I then felt I should add extra seal around the brackets where I had paired back the Perspex a little
too enthusiastically.
Once all the seal was in place, I finally refitted the domes and the stainless bezels with their
translucent edge seal and got it all as snug as I could.
I am very pleased with the result – these bezels are much better than the plastic ones and the car
deserves to have them! I also think the translucent edge seal is far better than the black edge seal
(unless your car is also black).
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on August 15, 2018, 12:31:05 PM
The problem with all this detailed work is that when it’s done right nobody notices, and when it’s not everyone does.

The level of detail you use nobody will notice it.  But we all know the work involved and appreciate your skill.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Furrari on August 15, 2018, 12:33:27 PM
I love the clearance in the cover around the screws retaining the tabs.  Again the small bits, the attention to detail that make the differance.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on August 15, 2018, 12:38:20 PM
More photos
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on August 15, 2018, 12:41:12 PM
And more (the last ones!)
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: seriph on August 15, 2018, 12:56:37 PM
Absolutely superb craftsmanship. An honest joy to behold. Thanks heaps for the great detail.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: Jez on March 29, 2020, 03:18:04 PM
Just ordered some new stainless steel parts for my car from Harringtons. Hopefully they will arrive soon, and I can spend some of this time we all have available replacing the hydrochromed parts - which are now into the third summer and still looking good btw.

I have ordered windscreen trim, grill surround, bonnet scoop trim and headlight bezels. Once they're done there will only be the boot handle to replace.
Title: Re: Jeremy's 2Fifty Cal story begins....
Post by: firefife on March 30, 2020, 10:26:54 AM
Good luck, mine all done bar the bonnet scoop surround, they weren't doing that when I got my bits. Be interested to see the scoop surround when you have got it, I made mine up out of aluminium sheet, not neat enough on curves but looks okay. Much better than my other attempts.