DNA Owners Club

DNA Owners => Build Threads => Topic started by: Phils99 on September 10, 2012, 12:10:13 PM

Title: Phils 4thirty build
Post by: Phils99 on September 10, 2012, 12:10:13 PM
Im getting excited now...

Just spoke to Roland and have booked a visit to DNA on Saturday.....and from the start, these guys are going to put themselves out and come into the workshop on a Saturday just to meet me! great customer service right from the very beginning of my project, as I am a failed Extreme builder, this is just fantastic ...just like everyone has said.

This is the start to my build thread and I plan to show the minute detail from how to strip the car down right up to the end as I feel that a lot of builders take the "simple to them" stuff for granted and dont actually show the detail, now I know that most of you will think that "how to remove a wing" is very straight forward, but I am aiming my thread at the total novices like myself and hopefully I will help some people on the way...

so here is the start and my first pictures...obviously I will be waiting for the kit to arrive, but I intend to start the stripdown when the weather turns as I am driving around for fun in the MR2 at the moment. (I think this is your car is it Steve? hope you don't mind)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/MR2tof430.jpg)

some more of the donor:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/20120610_121414.jpg)

Interior...notice its the SMT and I plan to try to fit the paddle shifters from a thrustmaster PC steering wheel!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/20120610_121438.jpg)

more to come....

Phil
Title: Re: Phils 4thirty build
Post by: beemaman on September 10, 2012, 01:09:25 PM
hi phils99

good to see your ready for your build thread now.good guys at dna buddy so you wont have the same problems as the extreme kits.

if you get time pop in im only 10 mins away from dna have a look at my 430 maybe get some ideas too :)

good to see another dna customer on here :)
Title: Re: Phils 4thirty build
Post by: Furrari on September 10, 2012, 03:15:20 PM
You don't say where you are based.  If you are coming down from Up North you are welcome to stop in Lichfield and see the Furrari (pm me for contact details).  The Furrari is a factory built car and is the one DNA use on their stand at shows at the moment.

Hope to see you at shows soon.
Title: Re: Phils 4thirty build
Post by: Phils99 on September 10, 2012, 03:22:16 PM
cheers guys,

I am based about 15 miles west of Hull, hence the Extreme purchase in the first place!

Beemaman - I have spent MANY hours going through your build thread again and again and I would love to see your car in the flesh, I am looking at hitting DNA at 10:30, so probably about 1-2 hours with them (as they havent got many cars in at the moment..) so I could pop round about 12-1pm? drop me a PM with your address/mobile if that would be OK mate.

Furrari - I was at the Newark show and saw your beauty on the stand

I cant wait to be able to attend the shows in my own DNA 430!

Regards
Phil
Title: Re: Phils 4thirty build
Post by: MADMAN on September 10, 2012, 06:16:23 PM
Im getting excited now...

Just spoke to Roland and have booked a visit to DNA on Saturday.....and from the start, these guys are going to put themselves out and come into the workshop on a Saturday just to meet me! great customer service right from the very beginning of my project, as I am a failed Extreme builder, this is just fantastic ...just like everyone has said.

This is the start to my build thread and I plan to show the minute detail from how to strip the car down right up to the end as I feel that a lot of builders take the "simple to them" stuff for granted and dont actually show the detail, now I know that most of you will think that "how to remove a wing" is very straight forward, but I am aiming my thread at the total novices like myself and hopefully I will help some people on the way...

so here is the start and my first pictures...obviously I will be waiting for the kit to arrive, but I intend to start the stripdown when the weather turns as I am driving around for fun in the MR2 at the moment. (I think this is your car is it Steve? hope you don't mind)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/MR2tof430.jpg)

some more of the donor:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/20120610_121414.jpg)

Interior...notice its the SMT and I plan to try to fit the paddle shifters from a thrustmaster PC steering wheel!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/20120610_121438.jpg)

more to come....

Phil
Yes thats my previous 430 and I dont mind you using any of my pics. in your build thread, good luck with your build, although I,m sure you will find it a breeze.
MADMAN (Steve)
Title: Re: Phils 4thirty build
Post by: Phils99 on September 15, 2012, 01:51:54 PM
well.....just driving back from visiting DNA (well my wife is actually driving!) and I must say, what great guys Roland and Brian are, they answered all my questions and took care of any of my concerns, so much so that I have now placed my order for a 4thirty full comp kit so all i need now is the mondeo fuel cap!

the 6 week countdown to collection now begins!

also, afterwards, I was invited to beemamans to see his completed car, for which I have read his build thread many times, and I have to say it's absolutely fantastic, the care and attention to detail is unbelievable, so much so that my wife who doesn't really rate kits cars also thought it was beautiful and it's now thrown the colour white into a maybe for my cars colour!

guys I am going to love being a member of this DNA club as you all seem to be great people, can't wait to get my car finished and at the shows.

regards
Phil
Title: Re: Phils 4thirty build
Post by: Phils99 on September 15, 2012, 05:05:51 PM
......having said that, I just searched the forum for mondeo and fuel and can't find any post that  tells you which mondeo fuel filler cover you need!

which "mk" mondeo do I need it from?
Title: Re: Phils 4thirty build
Post by: Furrari on September 15, 2012, 06:31:27 PM
Good to hear you've placed an order, I hope the Furrari gave you inspiration.  Even better to hear that your good lady is a convert.
See you at shows soon.  You don't have to be finished to join us (we even let Madman join us) :-)
Title: Re: Phils 4thirty build
Post by: Darren on September 15, 2012, 06:45:55 PM
Something to maybe think about is a power upgrade before the kit goes on, there's loads of options, turbo, supercharger, different engine.

Turbo and supercharger can go on the 18vvti without any major mods to the internals
 ;)
Title: Re: Phils 4thirty build
Post by: rudycob1 on September 15, 2012, 11:48:24 PM
Well done. Great to hear that you placed the order.
I have my appointment booked with DNA for the 28/9 and really looking forward to it.
We could be building our cars together. I will be in touch, just been busy with work.

Interesting advise on engine upgrade. Can you give me advise, opinion, suggestions, etc regarding turbo upgrades. Very interested to know more about this, including costs, power increase, who you recommend to do it, etc.

Rudy
Title: Re: Phils 4thirty build
Post by: beemaman on September 16, 2012, 08:48:18 AM
Hi phills99

Good to see you and your wife.and glad to see another DNA member.
You won't go wrong with car buddy you will think it's an airfix compared to extremes.

Can't wait to see the start of the build buddy and anything you need to know about prep or paint don't hesitate to contact me :) and thank you and your wife for the kind comments

Regards
Beemaman
Title: Re: Phils 4thirty build
Post by: rudycob1 on September 16, 2012, 09:26:14 AM
Hi Beemaman,
I too have been following your build and got the magazine article etc. on your fantastic car.
As I said I'm down at DNA on the 28/9. Is there any chance I could come and have a look at your car. Must say the attention to detail on your car is second to none and would appreciate seeing it in and getting some tips from you. My name is Rudy. If that is OK with you can you pm me and forward me your tel. Number. Thanks.
Title: Re: Phils 4thirty build
Post by: beemaman on September 16, 2012, 09:44:54 AM
No problem buddy Ile pm you my contacts and you can pop I'n and have a look at my build.

Anything i can do to help just give me a call :)
Title: Re: Phils 4thirty build
Post by: rudycob1 on September 16, 2012, 09:54:20 AM
Thanks Beemaman. Can you also pm your address please.
Appreciate your kind offer to help.
All you guys are fantastic and so glad I joined here.
I suppose we all have DNA to thank for getting us all together by producing such a fantastic product.

Title: Re: Phils 4thirty build
Post by: Darren on September 16, 2012, 12:21:29 PM
The Mr too brutal website http://www.twobrutal.co.uk/forum/ has a fair amount of info regarding turbo's and superchargers on the mr2 engine, Roland's old 430 had a supercharger, so a conversation with him will give you an idea of which way to go, after all he used it all the time.  ;D
Title: Re: Phils 4thirty build
Post by: DNA AUTOMOTIVE on September 16, 2012, 05:15:37 PM
DNA recomend that if you are going for turbos, superchargers or bolt on engine upgrades that the kit is fitted first, I had a supercharger fitted with oil cooler water, cooling injection, system piggy back ECU,  before fitting the kit it was when the kit was fitted that lots of it had to be changed and bits re fabricted on the supercharger kit to work for air intake and postion of mounting. http://www.tts-performance.co.uk/companyprofile.html
is the company that did the work.
Title: Re: Phils 4thirty build
Post by: Lord Beany on September 16, 2012, 05:39:16 PM
V6 is the best way to go for extra power, loads of torque and a better sound for a Ferrari replica.

Paul woods at Woodsport is the master.

A turbo is never gonna sound right for one of these cars, but if that is what you fancy, the mk2 mr2 turbo motor can also be slotted in place of the 1.8 4 pot.

I looked at all the options and decided on the V6. There are even three or four different v6 motors that can be fitted with different power and torque ratings. The v6 also has no problems with kit.

Beany ;D
Title: Re: Phils 4thirty build
Post by: rudycob1 on September 16, 2012, 10:25:26 PM
Hi. Many different opinions regarding V6 or turbo or supercharger. All have for and against but which one is the better value in terms of power, drive ability and sound?
What about engine change registration and insurance?
Comments and advise appreciated. I take on board DNA's advise as to fit either after the car is done.
Good advise and makes a lot of sense. Thanks.
Title: Re: Phils 4thirty build
Post by: Phils99 on September 18, 2012, 11:42:16 AM
Guys you may have missed my earlier question:

 I just searched the forum for mondeo and fuel and can't find any post that  tells you which mondeo fuel filler cover you need!

which "mk" mondeo do I need it from?

Furrari: we could pop into yours when I pick my kit up around middle/end of October if the offer is still there? it will be a Saturday or Sunday....we would like to see a yellow one up close....
Title: Re: Phils 4thirty build
Post by: Lord Beany on September 18, 2012, 05:56:31 PM
Mk1 Mondeo mate, should look like this.

Photo shoes mk1 flap and housing on the left and the DNA housing that it bonds into.

Beany ;D
Title: Re: Phils 4thirty build
Post by: steven on September 19, 2012, 09:25:40 AM
http://www.ebay.co.uk/itm/FORD-MONDEO-MK3-FUEL-CAP-FLAP-ANY-COLOUR-2001-2007-/390458488111?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item5ae923b52f
Title: Re: Phils 4thirty build
Post by: Phils99 on September 19, 2012, 10:54:11 AM
cheers guys,

Does it have to be a Mk1? would the MK3 one work?
Title: Re: Phils 4thirty build
Post by: Lord Beany on September 19, 2012, 11:18:18 AM
I was told mk1 only.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Darren on September 19, 2012, 05:21:36 PM
don't worry about it, i've got a few laying around, just tell me when you need one £10 delivered
D
Title: Re: Phils 4thirty build
Post by: Phils99 on October 01, 2012, 12:43:23 AM
well as rubycob has now started his stripdown, that spurred me on to get mine ready....
spent all day sorting out the garage and clearing shelves ready for the kit to arrive...

I have now driven into the garage in a blue mr2 and I will drive out in xxxxxxxx Ferrari f430!!

I hope to get some actual stripdown next weekend......

let the build begin!
Title: Re: Phils 4thirty build
Post by: Phils99 on October 01, 2012, 11:30:07 AM
>>>>>>>>>>>>>>>>>>>>>> LET IT BEGIN!!!!!!!!! <<<<<<<<<<<<<<<<<<<<<<<<<

Garage all cleaned out and shelf space created for the kit.

Car now tucked up in garage, ready to be given its new clothes!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/20121001_104448.jpg)
Title: Re: Phils 4thirty build
Post by: Phils99 on October 01, 2012, 01:39:40 PM
...also guys...I cant remember which thread I got this from, but I kept the picture...

I want to do something similar to this with my mirrors, my question is....what do they call these types of bolts and where can I get them from?

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/mirrors.jpg)
Title: Re: Phils 4thirty build
Post by: DNA AUTOMOTIVE on October 01, 2012, 02:31:25 PM
no its not done that way!
Title: Re: Phils 4thirty build
Post by: tenpin on October 01, 2012, 04:52:57 PM
...also guys...I cant remember which thread I got this from, but I kept the picture...

I want to do something similar to this with my mirrors, my question is....what do they call these types of bolts and where can I get them from?

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/mirrors.jpg)

The wiring connector in that picture looks like it's from a Cougar not an MR2....

 - tenpin
Title: Re: Phils 4thirty build
Post by: Phils99 on October 01, 2012, 05:01:34 PM
you are correct Tenpin, I found the image, its from Billywhizz scudo build...and DNA are saying we cant do it like this  :(

I just wanted to bolt the mirror on rather than bond in case they need to come off in the future...but bonding it is then!
Title: Re: Phils 4thirty build
Post by: Darren on October 01, 2012, 05:11:49 PM
look at tenpin's diary, he bolted, I think Wayne did aswell
D
Title: Re: Phils 4thirty build
Post by: rudycob1 on October 01, 2012, 05:24:54 PM
Fuel cap is ok from a Mk3 as I asked Brian on Friday. They all do the job. I just ordered mine.
Mirrors- can everybody give us advise on bolt option.

Going to look into aqua dipping option for components as I'm visiting a company that do this.
I will keep you updated if it's of interest to anybody.
Could be interesting for interior components, etc. carbon look, aluminium, etc.
Title: Re: Phils 4thirty build
Post by: Lord Beany on October 01, 2012, 06:00:59 PM
I bonded my mirrors on before the car went to paint and they had to be carefully removed with some piano so they could be painted off the car. Awkward angles to paint at if they are fitted apparently, although I believe madman has painted them insitu before?

If I did it again I would probably make up a plate with bolts welded to it that could be bonded to the inside of the mirror, then fitted to the triangular area at the top of the door with another plate on the rear, so they could be removed.

Having said that, they are perfectly strong enough having been bonded on and I'm sure either the mirror itself or the door panel would break before the bond failed, if it was to get whacked.

Beany. ;D
Title: Re: Phils 4thirty build
Post by: tenpin on October 01, 2012, 06:54:48 PM
look at tenpin's diary, he bolted, I think Wayne did aswell
D
Only partially correct -
The mirrors on the 5cudo are bonded to a plate, which is then bolted to the door. On the 3Sixty (and I believe 4Thirty) they are bonded directly to the triangular piece on the door.

 - tenpin
Title: Re: Phils 4thirty build
Post by: Phils99 on October 01, 2012, 09:57:28 PM
Here we go....my first day on the stripdown or 1.5 hours anyway....

I thought I would start nice and easy and remove the rear engine cover...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%201%20-%20011012/20121001_190349.jpg)

Need to remove this cover so that the 3rd brake light can be removed:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%201%20-%20011012/20121001_190837.jpg)

I then removed the bonnet:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%201%20-%20011012/20121001_193304.jpg)

then the rear lights:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%201%20-%20011012/20121001_194453.jpg)

I then decided to remove the rear wheel linings to get at the rear bumper fixings....I have never known so many clips and bolts needed to hold a piece of plastic in place!!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%201%20-%20011012/20121001_201947.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%201%20-%20011012/20121001_204201.jpg)

Can I discard both of the "nappies" now? do we not use either of them again?

Next it was now easier to get at the bumper retainers, so off it came!
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%201%20-%20011012/20121001_205643.jpg)

Dont forget to remove the number plate lights, I also then used a piece of cardboard to draw the cutout shape for the number plate lights so I can use this on the kit:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%201%20-%20011012/20121001_204848.jpg)

And thats it for now!! it will be weekend before the next update.....

how she looks now....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%201%20-%20011012/20121001_205655.jpg)
Title: Re: Phils 4thirty build
Post by: Lord Beany on October 02, 2012, 09:30:47 AM
Great start Phil.

It's incredible how quickly these cars come apart.

You don't need the wheelarch liners, but keep all screws and bolts etc as they can and will come in handy. Also any little plastic trims that you don't think you'll need, keep cos you never know.

When you said about removing the third brakelight, was that merely to sell it? As your comprehensive kit will include a new correct third brake light.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on October 02, 2012, 11:34:45 AM
yes beany...I have removed the brake light to sell separately from the engine cover....
Title: Re: Phils 4thirty build
Post by: MADMAN on October 02, 2012, 01:28:19 PM
yes beany...I have removed the brake light to sell separately from the engine cover....
wheel arch liners will sell, mr2roc also take out the vent from rear quater they sell from facelift like yours aprox £70 min.
MADMAN
Title: Re: Phils 4thirty build
Post by: Phils99 on October 02, 2012, 03:17:29 PM
all the parts are on MR2OC as we speak!!
Title: Re: Phils 4thirty build
Post by: Phils99 on October 05, 2012, 09:48:48 PM
OK guys, managed to get another 3 hours on the car tonight.

Its amazing how easy these are to strip! I am really enjoying this part of the build as its nice that everything just comes apart nicely!

Anyway, I know these may be boring to some of you experts, but hopefully of interest to the potential new builders to show how simple it can be, so lets crack on....front end to be stripped today, started with the inner wheel liners so that you can access all the bolts holding on the wings and bumper...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%202%20-%20051012/20121005_170638.jpg)

front bumper can now be removed...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%202%20-%20051012/20121005_172512.jpg)

This now allows me to get at the headlight bolts and remove these...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%202%20-%20051012/20121005_174003.jpg)

To get to all the wing bolts I needed to remove the front plastic and the wiper scuttle

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%202%20-%20051012/20121005_175531.jpg)

Offside wing removed...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%202%20-%20051012/20121005_175706.jpg)

Nearside wing removed...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%202%20-%20051012/20121005_180521.jpg)

Moving to the rear of the car now and I removed the offside rear quarter, this is bolted on, but you also have to drill out 3 rivets that are hidden under the trim at the top of the quarter

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%202%20-%20051012/20121005_185240.jpg)

And lastly the other rear quarter

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%202%20-%20051012/20121005_192211.jpg)

Thats it for now, next jobs will be to strip the doors down ready for cutting.

Cant believe i nearly have the car ready for dry fitting....after a handful of hours!!
Title: Re: Phils 4thirty build
Post by: Phils99 on October 08, 2012, 11:25:53 AM
got a little more time on her at the weekend, concentrated on the doors and the interior bits...

Door cards came off pretty easily and I never broke any of the clips!!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%203%20-%20061012/20121006_113903.jpg)

Need to remember what plugs in where as I intent to keep the tweeters in the new door cards

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%203%20-%20061012/20121006_114317.jpg)

next strip off the B pillar plastic so that I can remove the parts from above the storage boxes

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%203%20-%20061012/20121006_144339.jpg)

All removed!!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%203%20-%20061012/20121006_150003.jpg)

I then ran the build video part 1 on my tablet and walked round the car marking off the cuts and folds ready for Monday night when I hope to "cut 'er up" !

I bought an air saw and hooked it up to my compressor to test it...its amazing! what a great bit of kit! throw away the hacksaws!

oh I have also sprayed and sprayed all the nuts and threads of the front suspension with plusgas to hopefully release them easier.

I als owanted to spray the decat manifold with it, but I cant get the cover off without removing the O2 sensors, so I have ordered the socket for that....I nearly have everthing I need...

Thats it for now....thanks for looking
Title: Re: Phils 4thirty build
Post by: rudycob1 on October 08, 2012, 08:07:56 PM
Looking good.
I have done all the work now, the biggest bit was the front internal arches.
Now done and under sealed.
Sorting out the sound system and wiring now so that it's all ready.
Cleaned engine bay and all round the front. Sprayed wash bottle.
Ordered a header manifold from the USA to do away with the pre cats and get better sound from the engine when linked up to the DNA system.
Only thing left is the fuel pipe. Got the Mondeo cap and fitting but need advise on the length etc. so going the leave that for now.
Also managed to get a carbon fibre engine cover. Looks great.
Title: Re: Phils 4thirty build
Post by: Lord Beany on October 08, 2012, 08:11:14 PM
Looks like your enjoying yourself. ;D

Now the real fun starts, lol

Enjoy.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on October 08, 2012, 09:05:50 PM
rudy,

your storming ahead mate!!

I did the cutting tonight all apart from the doors , i want more time and daylight so probably do those at the weekend.

I started to strip down the rear brakes so that I can grease them up and hammerite all the metal parts as they are looking a bit flaky, then one of the bolts that hold the caliper on sheared off....bloody thing, gotta sort that out now.....

do you know where washer bottle gets repositioned? or do we have to wait until we get the headlight carrier brackets fitted.....good idea to paint it though...I might do that..

I am looking at decating my precat manifold as I think the replacements are very expensive for a manifold....I can spend that money elsewhere...

cheers for now...

Title: Re: Phils 4thirty build
Post by: beemaman on October 08, 2012, 09:28:54 PM
Hi Phills

Looking good buddy.just a thought when you strip down the suspension may pay to change the discs and pads too.put on grooved and drilled ones only cost about £160 for 4 discs and pads all-round and saves ever needed to strip off the wheels and dummy brakes ever again :)


Yes i think it best to re position the washer bottle when the headlamp carrier is on.

Keep the pics coming buddy :)
Title: Re: Phils 4thirty build
Post by: rudycob1 on October 08, 2012, 09:46:14 PM
Good suggestion about discs and brakes. Any suggestions were the best place to get them from is?

Phil
You're doing great, I think we are going along nicely and great to share ideas.
Title: Re: Phils 4thirty build
Post by: Phils99 on October 09, 2012, 07:11:39 AM
thanks guys....

beemaman: yea I am toying with the new discs and pads, but when I look at my rear ones they are hardly worn.....I think I will have to get front ones, so I guess for a bit more I can get a full set......I'll check ebay out...
Title: Re: Phils 4thirty build
Post by: Furrari on October 09, 2012, 08:53:30 AM
If you are changing the discs etc I can recommend EBC.  Not cheap but good quality.
If you are changing discs etc I would suggest changing the flexi pipes to stainless over braid type and change all the fluid as well as it's unlikely the previous owner did.
Title: Re: Phils 4thirty build
Post by: Lord Beany on October 09, 2012, 11:29:56 AM
I shall be doing a full upgrade on mine when she comes back. Grooved and drilled discs all round, ebc yellowstuff pads and braided hoses.

The misconception is bigger engine and more power means you need big powerful brakes. My new motor, although approx 100bhp more than standard, doesn't weigh a lot more than standard and that is what counts. If the vehicle is the same weight as standard then standard brakes will stop it the same.

By applying the brakes you are combating the weight of the car to slow it down, not the power of the engine.

However, bigger and better brakes do allow you to brake later and harder going into corners and reduce the risk of brake fade when working them hard.

The standard mr2 Roadster brakes are actually very good, at least, a set of braided hoses and some decent brake fluid will give a more positive feel to the brake pedal.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on October 14, 2012, 08:14:29 PM
only got a couple of hours on her today, but managed to firstly remove the door outer skin..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%204%20-%20141012/20121014_120802.jpg)

I then removed the inner door skin...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%204%20-%20141012/20121014_124839.jpg)

Completed the same on the other door...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%204%20-%20141012/20121014_124856.jpg)

I then folded over the top of the door so that the new door cards will fit...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%204%20-%20141012/20121014_130220.jpg)

I then cleaned up all the cut edges and hammerited them to stop rusting.

thats all for now....just counting down to the delivery...im hoping 2 weeks from now!
Title: Re: Phils 4thirty build
Post by: Darren on October 14, 2012, 09:43:26 PM
Beware! door cards need extra attention when shaping the door so they fit, each panel is slightly different. You'll need to do more work when they arrive.
D
Title: Re: Phils 4thirty build
Post by: Phils99 on October 14, 2012, 10:10:39 PM
thanks D for the heads up, I intend to make sure everything fits before it goes to paint....
Title: Re: Phils 4thirty build
Post by: Phils99 on October 15, 2012, 04:02:20 PM
WOW!!!

DNA just rang, my kit is ready for pickup on Saturday!!!!!!!!!!!

Thats just 4 weeks from order! great service once again DNA!!!
Title: Re: Phils 4thirty build
Post by: Phils99 on October 20, 2012, 06:13:16 PM
Got another couple of hours on her on Friday night....its just little bits here and there for me :-(

Anyway, decided to de-cat the pre-cats!!

I have been spraying the nuts with plusgas over the last couple of weeks...and they all came off with a little effort! Well pleased!!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%205%20-%20191012/20121019_185440.jpg)

Exhaust manifold on bench, ready to me attacked...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%205%20-%20191012/20121019_193248.jpg)

attack the catalyst!!!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%205%20-%20191012/20121019_194026.jpg)

One side removed....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%205%20-%20191012/20121019_200416.jpg)

Cant believe how much of this stuff comes out...this was just ONE  side....oh, and dont forget to wear a mask cos I dont think this stuff can be good for you...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%205%20-%20191012/20121019_200446.jpg)

Both sides now completed, just need to jetwash through to remove all traces...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%205%20-%20191012/20121019_201607.jpg)

GUTTED....

Just looking at my engine, it has LOADS of oil coming out of the head gasket....this is gunna need replacing...thats a very expensive garage job so I think I will have a go at this myself.

Found this thread that states that it is possible to remove the head with the engine in the car!!

http://www.toyotanation.com/forum/20-mr2-forum/418240-mk3-mr2-piston-ring-change-without-removing-engine.html (http://www.toyotanation.com/forum/20-mr2-forum/418240-mk3-mr2-piston-ring-change-without-removing-engine.html)

Watch this space whilst I attempt this..gotta get to bed now, as I need to be up bright and early to go collect my kit from DNA!!!!!!!
Title: Re: Phils 4thirty build
Post by: Phils99 on October 20, 2012, 06:20:32 PM
Guess what now lives at my house!!!!!!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%206%20-%20pick%20up%20kit%20201012/20121020_154959.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%206%20-%20pick%20up%20kit%20201012/20121020_163607.jpg)

Cant do much with it though cos I have LOADS of work to do on the car first...here is my plan:

1. fix the head gasket leak - this will take loads of my time....
2. de-rust all underneath and anywhere I find any more
3. mask off, prime and spray the front and rear black so no blue is visible even with covers open.

Ill keep updating as usual, got to take the wife out now for a bit of quality time together!
Title: Re: Phils 4thirty build
Post by: Darren on October 20, 2012, 06:59:21 PM
It's imperative that ALL the ceramics from the precat are removed, this will get into the oil from the egr valve and kill the engine.
 Shame about head gasket, they're not known for this, are you sure it's not comng from somewhere else? Paul at woodsports may be able to offer some advice.
 Glad to see you've got your kit, they're a breeze to fit, I've had the base panels on and off several times for various test fits with other components.
 How does the grp quality feel when compared to the extreme kit?
D
Title: Re: Phils 4thirty build
Post by: Lord Beany on October 20, 2012, 07:11:10 PM
Paul still has my old engine sat at Woodsports if it turns out you need a replacement.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on October 20, 2012, 10:18:24 PM
D, Yea, i am gunna flush the manifold out with my jetwash to make sure...Its defo the head gasket as its totally dry above, but wet with oil from the head/rocker cover join running down the block :-(

If you look at the link I attached, check out his later photos, it looks like he had gasket and seal problems....

The quality of this kit makes the Extreme kit seem like paper! and all the extra parts, wow what a kit this is, looking forward to fixing the engine and getting on with it.

Beany, thanks mate, I will let you know if I mess it all up!!
Title: Re: Phils 4thirty build
Post by: Phils99 on October 21, 2012, 06:27:27 PM
HELP!!

I am well on the way to removing the cylinder head to replace the gaskets and I need some specialist tools....

Any of you guys in the yorkshire area.....

I need a crankshaft pully bolt remover something like this:
http://www.ebay.co.uk/itm/VS1013-SEALEY-Crankshaft-Pulley-Remover-Installer-Ford-Sealey-VS1013-/160874747609?pt=LH_DefaultDomain_3&hash=item2574e1d6d9 (http://www.ebay.co.uk/itm/VS1013-SEALEY-Crankshaft-Pulley-Remover-Installer-Ford-Sealey-VS1013-/160874747609?pt=LH_DefaultDomain_3&hash=item2574e1d6d9)

and I need a crankshaft pulley remover like this:

http://www.ebay.co.uk/itm/SEALEY-Ribbed-Crankshaft-Auxilary-Pulley-Remover-VS785-/380319765289?pt=UK_Hand_Tools_Equipment&hash=item588cd31329 (http://www.ebay.co.uk/itm/SEALEY-Ribbed-Crankshaft-Auxilary-Pulley-Remover-VS785-/380319765289?pt=UK_Hand_Tools_Equipment&hash=item588cd31329)

I dont wanna pay £150 - £200 just for the 2 times I would use these....so I wonder if only of you local guys have the tools I could borrow?
Title: Re: Phils 4thirty build
Post by: rudycob1 on October 21, 2012, 08:14:59 PM
Hi Phil
I have a pulley remover but it's not like the one in the photo.
It's a normal one so don't know if it will do the job, but you are welcome to borrow it.
If you do let me know as I'm off on holiday on Thursday.
Let me know mate so I can look for it as I have not used it for a long time.
Just a question. If you have a blown head gasket usually you will get oil and water mixing together, have you got that?
Title: Re: Phils 4thirty build
Post by: Phils99 on October 21, 2012, 09:55:41 PM
Cheers Rudy,

Im in London until thursday now :-(

I dont think I have oil and water mixing, I just have loads of oil running down the engine block...which I didnt notice until I removed the exhaust manifold.
Title: Re: Phils 4thirty build
Post by: rudycob1 on October 21, 2012, 10:07:47 PM
Seems strange. Silly question. Have you tried cleaning the block and seeing if you get any oil coming out once you start the engine? Could it be that a previous owner had a leaking rocker cover and only cleaned the head as he could not get to the block? Are you losing any oil or burning any oil? Have you tested the compression? Worth trying things out before you strip it all down. Just trying to help!
Title: Re: Phils 4thirty build
Post by: Phils99 on October 21, 2012, 11:04:25 PM
too late now...I have just about stripped it down!
 since it's been in the garage, I have noticed a small pool of oil on the floor directly under the leak, so yes, it's still leaking....

I only need to get the pulley off, then I can remove the timing chain cover, chain and rockers to then let me remove the head!!

this job takes for ever, no wonder garages charge a fortune to do it......I hope I can get it all back together and working......
Title: Re: Phils 4thirty build
Post by: rudycob1 on October 21, 2012, 11:14:35 PM
Let me know if you get stuck for the pulley remover. I'm away for 10 days from Thursday.
Title: Re: Phils 4thirty build
Post by: Phils99 on October 22, 2012, 10:33:06 PM
found a universal pulley holder on amazon for £32!
here http://www.amazon.co.uk/exec/obidos/ASIN/B006B3Q9KU/ref=ox_ya_os_product (http://www.amazon.co.uk/exec/obidos/ASIN/B006B3Q9KU/ref=ox_ya_os_product)

bought it and hopefully it will help get the cylinder head off!!
Title: Re: Phils 4thirty build
Post by: Phils99 on October 29, 2012, 10:31:22 PM
well the universal pulley holder came so I gave it a go....and it worked a treat!
so tonight I managed about 1.5 hours in the garage and managed to remove the timing chain cover and remove the camshafts.....then I saw the bolt heads that hold the cylinder head on....so back on ebay to order a M12 bi-hexagonal bit with 1/2 inch drive....one of these:
http://www.ebay.co.uk/itm/250899435264?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649 (http://www.ebay.co.uk/itm/250899435264?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649)

I am slowly getting closer to that cylinder head gasket.....just hope I can remember where everything goes when it come to rebuild!!

I'll keep you posted.....
Title: Re: Phils 4thirty build
Post by: Phils99 on November 18, 2012, 08:05:33 PM
ok guys, its been a while since I have posted, as we are in the midst of sorting a house move out up to Durham...yep Im leaving yorkshire and moving to live nearer my wives family....

Anyway....I have eventually gathered all the tools I needed to remove the cylinder head and have got down to see a nasty gasket that was the cause of my oil leak! here are some pics...

Start of engine stripdown still on the car!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/day%207%20-%20211012/20121021_110313.jpg)

Loads of wires connect all round the engine to all the sensors, spark plugs, injectors etc..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/day%207%20-%20211012/20121021_151604.jpg)

Rocker cover removed....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/day%207%20-%20211012/20121021_114112.jpg)

Lining up the timing chain and camshafts for when i refit them...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/day%207%20-%20211012/20121021_165712.jpg)

Right tool for the right job...had to buy the tool to remove the head bolts...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%208%20-%206%20hours/20121102_181754.jpg)

Look at all these parts!!!!  hope I can remember where they all go!!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%208%20-%206%20hours/20121102_180555.jpg)

After many hours labour, eventually get to the nasty gasket...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%208%20-%206%20hours/20121102_182934.jpg)

Clean off the head ready for the new gasket...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%208%20-%206%20hours/20121102_183503.jpg)

...new gasket in place

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%208%20-%206%20hours/20121102_183651.jpg)

OK after this I didnt get much time to work on the car for a bit, then I had a full day so I went through the rebuild and it went very smoothly....until I finally finished, it was now the time to fire her up...and...she wouldnt start....gutted..

I went back and rechecked everything but she still wouldnt start. Looking at the plugs they were dry, so no fuel was getting through....after a bit of googling, I found info on maybe the fuel pump fuse had blown!. Also the cooling fans were running as soon as you turned ignition on????

So I went through every fuse in the engine bay and the ones near the frunk...and all were fine :-(

I decided I needed to buy a OBDII reader, as these cars try to tell you if something is wrong, so off to ebay again....one now ordered and I await delivery...

OBDII reader delivered on Saturday.....so today Sunday 18th Nov off I go to the garage.

I plug in the OBD reader, turned on ignition and waited for the communications with the car and the OBD........success!! it talks to the car!! AND it tells me I have error P0115 which is the Electronic temp sensor failure....googling this, I found that this can lead to car not starting and fans running!! looking good....now where the hell is this sensor....looking through my MR2 electronic manual, it shows me its left hand side of engine block, underneath the wiring junction...hmmm lets take a look!
ahha! I found that I had missed connecting the plug back onto the temp sensor, lets plug that back in....moment of truth...turn ingnition on...no fans running, turn key HEY PRESTO!! she starts first time!!

BEST THING I HAVE EVER BOUGHT IS THE OBDII READER!!

so, my head gasket change is now complete after about 12 hours of my time, I can see why this would cost you a fortune at a garage....it still cost me a bit, but I have also carried out a complete service as well.

I had to buy the following:

Head gasket set - £115
Head gasket bolt remover - £13.40
Air and oil filter kit - £14
Spark Plugs - £8.48
New drive belt - £9.48
Oil - £25
Coolant - £10
Driveshaft wheel removal tool - cant remember, I thin it was £30
Torque wrench - £18.70
OBDII - £20

So, all in all around £265, but my tool kit has grown since doing it!!

So....back on track to do the DNA kit now!!
The rest of today I used to strip down the rear suspension and put the DNA springs in.

I have also hammerited all the surface rusted metal parts after wire brushing them..

Rear suspension removed, just need to compress that spring so the top doesnt kill me when I remove it!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%209%20-%20181112/20121118_122856.jpg)

Old spring removed and sat next to DNA replacement (new spring on the left!!)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%209%20-%20181112/20121118_124400.jpg)

New spring in place....simple to install

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%209%20-%20181112/20121118_125525.jpg)

I then dismatled the brake calipers as I have all new disks and brake pads to fit.

Thats it for now.....hope I didnt bore you all to death!!

Title: Re: Phils 4thirty build
Post by: Lord Beany on November 18, 2012, 09:23:51 PM
Good job Phil,

Props on the head gasket replacement, not many people would be willing to try it.

If you can manage that, the build will be a breeze. Mind you, if you are moving to Durham, how long will it take for you to go knocking on Mr Wood's door for a little V6 action? :P

Look forward to seeing the progress.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on November 18, 2012, 10:21:00 PM
lol....cheers for the comments my lord...

I have checked on the map and my new house if we get it is actually 2.8 miles from Woodsports!!

....dont tempt me!!!

Hey if I get my house before you pick up your car (im hoping to get it before the end of December..) you could pop in to see us for a cuppa before your journey home!

I am also thinking of doing my 4thirty in yellow, so it would be nice to se one up close especially with a V6 in it!
Title: Re: Phils 4thirty build
Post by: rudycob1 on November 18, 2012, 11:01:30 PM
Hi Phil
Great job on the engine. Glad you got it sorted and back on track. Shame to hear that you are moving up north. Should get my kit this week with a bit of luck. Very excited. You must pop over before you go up north and we can have a cuppa and a chat and compare notes. Good luck with everything.
Title: Re: Phils 4thirty build
Post by: Phils99 on November 19, 2012, 08:11:40 AM
sounds good mate, let me know when you get your kit...
Title: Re: Phils 4thirty build
Post by: Furrari on November 19, 2012, 08:51:57 AM
Phil
I think your spellcheck needs checking.  Monenda yellow is spelled YELLOW. :-)
Most impressive colour, always attracts attention, or is that 'cos it's a Furrari.
Title: Re: Phils 4thirty build
Post by: Lord Beany on November 19, 2012, 10:11:46 PM
A light liquid refreshment is always appreciated on a long journey, thanks Phil. I'll PM you when i know i am collecting.

It's gonna be a whistle stop tour on the way back down south as i shall be calling in on Madman too.

Aren't you and Rudycob1 both in Madmans neck of the woods at the moment? May be a chance to all meet up.

We'll have to see.

Beany ;D
Title: Re: Phils 4thirty build
Post by: rudycob1 on November 19, 2012, 10:28:08 PM
I'm up for that. Let's get something sorted. All welcome to come over to mine. I'm sure I can arrange drinks ( non alcoholic obviously :-) ) and snacks. Sounds like this could be a plan.
Title: Re: Phils 4thirty build
Post by: Phils99 on November 20, 2012, 07:00:12 AM
count me in!
 
We can we the head of a new born V6 4thirty ( with tea of course!)
Title: Re: Phils 4thirty build
Post by: beemaman on November 20, 2012, 08:46:13 AM
wished i lived closer now would be nice to all meet up :)

great to see your tackling the head issue phills :) :) wont be long til its kit fitting time...
Title: Re: Phils 4thirty build
Post by: Phils99 on November 20, 2012, 09:03:39 AM
i wanna get the kit dry fitted as soon as i can because i will need to car trailer it up to durham when we move....dont want to have to make 2 journeys, on with the car and one with the kit!!

By  the way, do anyone of you guys in the yorkshire area have access to a car trailer?
I would pay for the hire of course....
Title: Re: Phils 4thirty build
Post by: MADMAN on November 20, 2012, 10:28:40 AM
Hiya Phil,
             I,ve got an A frame you can use, fit body and leave front bumper off and you can tow it no probs. failing that I think there is a trailer hire firm in Swillington near leeds, cant remember their name. google will find it.
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on November 20, 2012, 09:57:46 PM
cheers steve, might pop and have a look at that when we are moving, that would be brilliant!

regards
phil
Title: Re: Phils 4thirty build
Post by: Phils99 on November 29, 2012, 11:19:35 PM
got some time on her last saturday....this seems to be taking AGES but I want to get all the car de-rusted so that when I do start fitting the kit, I know I have a good car underneath.

Rear suspension assembled minus the caliper and coated with waxoil based paint and hammerite on the main metal parts

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2010/20121125_124224.jpg)

Here is the front suspension before stripping down, looks like I need to replace the suspension boots :-(

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2010/20121125_124252.jpg)

Stripped all the front suspension down, but had a rusted bolt holding on the drivers wishbone so I had to cut it off with the grinder....the wishbone gets replaced anyway! Just need a new bolt now.....

more soon
Title: Re: Phils 4thirty build
Post by: Phils99 on November 29, 2012, 11:36:43 PM
more time tonight, so I thought I would look at cleaning up the front wheel arches and set about assembling the front suspension.

Here is the passenger side all stripped down

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2011/20121129_181302.jpg)

here is some detailed pics of the new wishbone, new ball joint and track rod extensions fitted. After researching on here (from Lord Beanys build thread!) these are installed the right way up.

I need to work on the drop links to make the rubber and metal disk smaller so that they fit into the new hole in the wishbone. Mine dont line up very well, but I guess I will be able to get the nut on the end with a little fiddling.

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2011/20121129_202847.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2011/20121129_202855.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2011/20121129_202906.jpg)

I also decided to bring my fake disks inside and sit watching telly whilst assembling them!

Again, using Lord Beanys info, I assembled these as follows:

obtain the following:
40 x M5 Dome headed Allen bolts. 20mm long.
80 x M5 full nuts, two fitted between the bell and the disc to create the effect of thickness.
40 x Nyloc Nuts for the rear, fitted behind the disc.

Assemble as follows:

first push the bolts through each hole in the bell and secure with one of the nuts

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2011/20121129_212438.jpg)

Add the second nut onto the bolt

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2011/20121129_212429.jpg)

now fit the bell to the disk and secure with the nyloc nuts

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2011/20121129_213737.jpg)

Completed!! Just 3 more to do... :-(

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2011/20121129_213752.jpg)

Next jobs are:

1. fit wheel hubs to the wishbones - awaiting delivery of a 19mm ring spanner to get these off the old wishbones!
2. refit suspension - awaiting delivery of new suspension boots
3. fit wheel spacers and fake disks to see how they look
4. get car onto the big wheels!

Probably next weekend before I get any more time as we have to go up to Durham to snag the new house this weekend...



Title: Re: Phils 4thirty build
Post by: beemaman on November 30, 2012, 07:37:24 AM
Nice work phils

It feels good when it starts coming together :) you excited buddy

Keep the pics coming buddy we love some great builds
Title: Re: Phils 4thirty build
Post by: seriph on November 30, 2012, 09:22:23 AM
yummy   -   great work mate
Title: Re: Phils 4thirty build
Post by: Phils99 on November 30, 2012, 10:16:16 AM
cheers for the comments guys....I just wanna get some bodywork on the baby!!

Sick of de-rusting and fixing all the bits and bobs....ah well at least I will end up with a sound car underneath it all when I have finished!!
Title: Re: Phils 4thirty build
Post by: beemaman on November 30, 2012, 12:02:29 PM
it makes a better job buddy and you know in your head that its been done properly,cant beat a tin of black underseal :)

wait till you get kit on you will wet your pants and when its been painted you will wet them some more :)
Title: Re: Phils 4thirty build
Post by: Lord Beany on November 30, 2012, 01:34:55 PM
Hey Phil,

Glad my build thread is helping you out mate.

Just a quick point on your dummy discs, The front pair will require the bolts grinding down on the rear otherwise they will foul on the original brake caliper as they start to rotate. The rears are fine due to the wider spacers.

Cracking prep work though, keep the updates coming.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on November 30, 2012, 03:44:13 PM
great advice Beany, Ill get that sorted when I fit them.....
Title: Re: Phils 4thirty build
Post by: beemaman on November 30, 2012, 05:30:20 PM
Hi Phills

Full of info is our beanster :) glad you can get advice from other peoples builds that's why this website is so good.

Keep them pics and info coming buddy :)
Title: Re: Phils 4thirty build
Post by: Lord Beany on November 30, 2012, 08:15:36 PM
Just one more point before you bolt everything up Phil, did you shorten the track rod by 10mm before adding the extension?

Reason i say is i missed this part and didn't realise until i tried to push the car back into the garage, but couldn't, because the wheels were toeing out too far. Had to take it all apart again after a call to R&B. ::)

Wouldn't want you to waste the time that i did.

Beany ;D

Title: Re: Phils 4thirty build
Post by: Phils99 on December 03, 2012, 09:48:58 PM
not much done tonight....keep getting hit by rusted bolts etc....they just take so much time trying to free up before I make the decision to cut them off and replace them :-(

Anyway, got my replacement front suspension bumpers, here is a new and old pic..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2012%20031212/20121203_181105.jpg)

I then fitted them to the suspension and reinstalled onto the car. I have also fitted the lowering bracket as you can see...lovely piece of engineering these brackets, then mould intoi the exact shape of the suspension leg! good old DNA!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2012%20031212/20121203_193138.jpg)

Next I removed the hub bolts, looking at other threads, it says you tap them out....Im always worried that I ruin them (as you will need them later to replace the original wheels for spray shop), so I just gently tapped them until they just dropped out! I really thought I would get a load of rusty ones that wouldnt move but they all came out with ease!
This pic shows what the removed bolt looks like

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2012%20031212/20121203_195200.jpg)

Next I painted up the hub with hammerite and then just hung it on the new ball joint to dry, I will fix it all up next time I get to play!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2012%20031212/20121203_200459.jpg)

I must remember, as Beany said, to cut down the trackrod arms by 10mm....thanks Beany...

thatsall for now....hopefully get a full day next weekend and get this suspension all completed and refit!!
Title: Re: Phils 4thirty build
Post by: beemaman on December 03, 2012, 10:19:37 PM
Nice work phill

 I hated those rusty old bolts on mine.seems that it's common on mr2s lol

Won't be long and it will have all suspension done :)

Keep the pics coming buddy :) :)
Title: Re: Phils 4thirty build
Post by: rudycob1 on December 03, 2012, 10:36:49 PM
Looking good. Great work.
Title: Re: Phils 4thirty build
Post by: Lord Beany on December 04, 2012, 09:21:08 AM

 I hated those rusty old bolts on mine.seems that it's common on mr2s lol

You've got the Cougar to tackle soon mate, those nuts and bolts have been there much longer. Lol.

Great seeing yours and Rudy's builds side by side Phil. It reminds me of back when Beems and I started our 430's, good times, not only did we build a couple great cars but a great friendship too.

DNAOC is a great club to be a member of .

Keep those updates coming.

Beany ;D
Title: Re: Phils 4thirty build
Post by: beemaman on December 04, 2012, 11:10:33 AM
hey beany

 your gonna make me blush :) but you are right buddy it was a great year when we both had our builds on here and was working side by side with ideas etc and i agree we made great friends too and hopefully we will get to see eachother more at the shows next year with our cars again :)

so rudy and phil we want to see you as great friends too after you have built your 430 cars :) one thing i can say is the people ive met through the dna forum etc have been great to deal and talk too and if anyones ever by me down here in this cold part of the midlands then your welcome to pop in for a nice tea or coffee and a a warm :) :)

back to those rusty bolts now everyone :)

Title: Re: Phils 4thirty build
Post by: Phils99 on December 04, 2012, 01:02:18 PM
he he....yea this is one of the best forums for car builders I have come across....EVERYONE is very helpful and not condescending in any way for people like me who are new to this and have to do lots of research before I can tackle a job....I hope that I get mine finished for next years shows (at this rate, it doesnt seem like I will!) where we can all meet and share build stories

Wayne, stop reminding me about the rusty bolts!!!!
I hope I have uncovered the last one now and can start the reassembly with no issues...
Title: Re: Phils 4thirty build
Post by: rudycob1 on December 04, 2012, 06:58:55 PM
Hey guys
I second everything that you all say and I for one have set a target to get it done by the summer with the help of my friends.
Mind you I still need to tackle my rusty bolts, hope that they are not to bad!!
Spoke to Roland yesterday and as always he answered all my questions and put my mind at rest that I'm on the right track. I want to try and get all the dusty jobs out of the way first. Than clean up all that white dust from everywhere and continue in a clean environment.
Got a few more goodies, blue light conversion for dashboard, etc.; chrome surround for gear lever gaiter,
And managed to get all the VIN Plate stickers made for me with the proper numbers. They look fantastic.
Title: Re: Phils 4thirty build
Post by: Lord Beany on December 04, 2012, 07:53:45 PM
Photos please Rudy. Are these the vin stickers made by Sean, or elsewhere?

Pop the details in your build, so we're not hijacking Phil's.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on December 10, 2012, 08:54:55 PM
Well it seemed like a LONG day messing with the front suspension and reassembling it all nicely painted and with new bolts where I had to cut them off.....I also trimmed 10mm off the track rod ends like this...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2013%20-%20091212/20121209_125007.jpg)

This is so that the extender fits onto the thread further like in this picture or it leaves the front wheels facing outwards..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2013%20-%20091212/20121209_125038.jpg)

I couldnt refit the track rod ends correctly though as the hole in the top for an allen key has rusted up so I cannot tighten them....ordered 2 new ones...jeez the whole car is gunna be new when I have finished!!

Anyway I fit them in without tightening them up, just so that I can refit the wheels....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2013%20-%20091212/20121209_154536.jpg)

Then for a change I though I would have a go round the back end at the exhaust, first I refit the heat shields after I had painted the top one with heat resistant paint...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2013%20-%20091212/20121209_162000.jpg)

I then started assembling the exhaust and found that the brackets when tightened up didnt secure the exhaust so I had to enlarge the slots from this:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2013%20-%20091212/20121209_163044.jpg)

To this:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2013%20-%20091212/20121209_163151.jpg)

Anyway after much juggling and searchng through this forum I managed to assemble the exhaust I think correctly like this..let me know if its wrong guys!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2013%20-%20091212/20121210_203437.jpg)

I figured out that the L shaped pins with washers welded on go onto the bumper bolts like these two pics show:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2013%20-%20091212/20121210_203445.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2013%20-%20091212/20121210_203500.jpg)

I then used the U bolts with the threads welded on, the shorter one I worked out goes here:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2013%20-%20091212/20121210_203453.jpg)

The longer one, goes here BUT I cant get the exhaust to fit into it as the pipe going over to the right catches on the bit of bodywork sticking out, now have I fit it incorrectly? can I remove the bit of bodywork sticking out to make the exhaust fit easier?

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2013%20-%20091212/20121210_203519.jpg)

Thats all for now.....

Title: Re: Phils 4thirty build
Post by: beemaman on December 11, 2012, 03:46:34 PM
hi phills

 good work buddy hope you got all the exhaust sorted :)i love to see you guys building cars and i cant wait to start mine too :)

 keep the updates coming buddy :)
Title: Re: Phils 4thirty build
Post by: Phils99 on December 14, 2012, 09:12:43 PM
Got a few hours tonight so I thought I would fit the front bracket and the two light carriers

you will have to move the ABS sensor on the passenger side when fitting the light carrier bracket, but I found if I just bent the frame that the plug is mounted on a little it can remain on the same bolt.

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2014%20141212/20121214_185325_zps0deb5295.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2014%20141212/20121214_185336_zpsdd90dd74.jpg)

I then thought I might just mess about with one of the panels instead of mechanical stuff!!

So I hung the door on, had to adjust it a little to fit correctly but it ended up snug!

you can just make out the faint line where the hole for the door handle should be so i drew round it with a pencil

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2014%20141212/20121214_192906_zps669cd337.jpg)

I very roughly cut it out just so I can mess with the handle later

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2014%20141212/20121214_195447_zps85f0d6fa.jpg)

thats all for now....just thought I would lay the front clip on to make me feel better...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2014%20141212/20121214_195501_zps0cc59446.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2014%20141212/20121214_195511_zps065aa6f1.jpg)

Thats all for now
Title: Re: Phils 4thirty build
Post by: Phils99 on December 17, 2012, 12:12:23 PM
Just realised that I am gunna need 10 wheel bolts for the front wheels to fit onto the spacers.

Any of you "experts" remember which wheel bolts you used for the front wheels? Sizes? links?

I have searched the forum, but nothing came up....
I need to order some.....
Title: Re: Phils 4thirty build
Post by: beemaman on December 17, 2012, 12:19:43 PM
im sure dna can provide you with some but they may need cutting down to lengh if cant get correct size,i did cut mine down as were too long but were fine after that..
Title: Re: Phils 4thirty build
Post by: tenpin on December 17, 2012, 04:08:02 PM
On my 3Sixty they were
M12  1.5

Well, that's what it said on them!

 - tenpin
Title: Re: Phils 4thirty build
Post by: Phils99 on December 17, 2012, 04:56:59 PM
cheers guys, Ive ordered a set of 10 of the 'bay, £11!
Title: Re: Phils 4thirty build
Post by: Lord Beany on December 17, 2012, 08:36:47 PM
I'll have a look for the details of the ones I bought. Angle of taper and length, although I did have to cut them down a little.

I also managed to sheer one off as it's hole lined up with one of the bolts from the rear and they bound tight together causing the wheel bolt to sheer.

Beany  ;D
Title: Re: Phils 4thirty build
Post by: Lord Beany on December 17, 2012, 08:45:37 PM
Front wheel fitted, using Bolts. I bought 26mm bolts (All fixed 60degree taper, by the way. 17mm socket.) I

That's from my build thread mate, I'm sure thread size is in there somewhere, but can't find it at moment.

Beany  ;D
Title: Re: Phils 4thirty build
Post by: DNA AUTOMOTIVE on December 18, 2012, 08:37:54 PM
(http://i42.photobucket.com/albums/e303/dna-engineering/dnaxmascard1_zps462f28b8.jpg)
Title: Re: Phils 4thirty build
Post by: Phils99 on December 18, 2012, 10:21:29 PM
cheers roland and brian, have a great xmas yourselves and a very good new year...looking forward to watching dn8 build threads in 2013.....
Title: Re: Phils 4thirty build
Post by: Phils99 on January 03, 2013, 05:21:39 PM
Very slow progress at the moment...we are packing like mad for the move up to Durham....we have the dates now 31st Jan and 1st Feb, I will then become a geordie!!
Not getting much time on the car, my main goal is to get the door panels screwed on and then lay the back end on so that I can car trailer the car to Durham.

Here is my piece of bar with the twist added!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2015%206%20hours/20121221_191511.jpg)

Here I have drilled the holes in the door handle so that I can bolt the bar to it

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2015%206%20hours/20121221_192257.jpg)

I then marked the door for the cut-outs...the door will need a bit of work on the edge!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2015%206%20hours/20121221_194516.jpg)

Drilled holes in the corners and then used my air saw to join up the holes...Ive left these rough at the moment as I will clean them up later

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2015%206%20hours/20121221_194716.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2015%206%20hours/20121221_201620.jpg)

I then did the same on the other side...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2015%206%20hours/20121230_100556.jpg)

After screwing the doors on, I then just laid some other panels on to see what it looks like...I also took the car off the jacks, and its now VERY low to the floor!!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2015%206%20hours/20121230_125613.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2015%206%20hours/20121230_125903.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2015%206%20hours/20121230_125925.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2015%206%20hours/20121230_125947.jpg)

Thats it for now....the next update will be me shipping it up to Durham as I wont get any more time on it between now and then....sorry for the slow build!

Title: Re: Phils 4thirty build
Post by: rudycob1 on January 03, 2013, 05:46:26 PM
Nice work Phil.
You will get there in the end and it will be worth it.
I'm working on it like crazy as I have a target of first week in Feb for body shop.
Keep us updated and good luck with your move.
Hopefully I will see you at the shows.
Take care
Title: Re: Phils 4thirty build
Post by: howza on January 03, 2013, 05:57:10 PM
Hi Phil, nice work on the car. You will need to be a bit further north to become a true Geordie. When you get moved in, if you get stuck on anything just let me know as I'am just north of Newcastle. Sold my 430 mind and now sorting a DN8 but did the full build including roof install ( with help from Madman) . Happy to help as all on here are. Best regards and welcome to the northeast. Howza
Title: Re: Phils 4thirty build
Post by: Phils99 on March 18, 2013, 09:01:25 PM
REPOSTING THIS AS I PUT IT IN THE WRONG THREAD!!

IM BACK!!

We have now moved in and I have spent the last 5 weekends doing "man" jobs around the new house.

These are now mostly done, so I decided to have a day on the car to get a bit done!
Im so far behind now, but anyway its an hobby not a rush job!

I think I am aiming for next spring for it to be ready now......

Anyway, I removed the panels that I had quickly bolted on so that I could transport the car up to Durham so that I could carry on where I left off.....

So I decided to fit the kits wheels, starting with the back ones....here Im splitting the supplied rear spacers..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2016/20130317_123816_zps62168c54.jpg)

here is the inner part of the spacer, you secure this to the existing wheel threads using the shorter wheels nuts.

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2016/20130317_124551_zpsdf6fc129.jpg)

here is the plate for the fake caliper mounted

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2016/20130317_134427_zps4322d8dd.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2016/20130317_134440_zps348eea8a.jpg)

Here is the inner spacer fitted

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2016/20130317_135021_zps0ef6ea31.jpg)

The outer spacer is them allen bolted back onto the inner spacer and the fake disk then fits it between the spacer and the wheel.

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2016/20130317_140035_zps74ded78f.jpg)

here is the front one fitted.....this needs the existing bolts removing and the new bolts inserting from the rear.

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2016/20130317_161211_zpsab22b089.jpg)

thats it for now....be a couple of weeks before I get any more time on the baby....
Title: Re: Phils 4thirty build
Post by: beemaman on March 19, 2013, 11:40:33 AM
good to see you back buddy and hope you can get the time on her now your all sorted..

keep the updates coming buddy :) :)
Title: Re: Phils 4thirty build
Post by: Phils99 on April 05, 2013, 11:43:50 AM
managed to get a little more time on her...decided to have a go at the petrol pipes...

You need to release this bracket as it holds the main filler pipe and the breather pipe..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2017/20130326_190812_zpsa0452948.jpg)

A similar bracket is underneath the car that holds the breather steady..didnt get any pics of this..

After removing the filler and pipes, I cut a length off the breather to use to help me attach the new supplied pipe with:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2017/1b53c593-3dd2-4d1c-958c-285fd13c887a_zps159234b5.jpg)

Which I then connected to my new pipe:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2017/20130331_190656_zps4d6e7314.jpg)

I then took a piece of rubber tubing I had a rivited it around the hole to stop the pipes scraping on the metal:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2017/20130331_193232_zpsee9d0c48.jpg)

The two pipes were then positioned until I was happy and pushed through the hole ready for the kit!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2017/20130331_202719_zpsfbad9a2e.jpg)

So thats another ticked off my very long list of jobs to do!

another update very soon
Title: Re: Phils 4thirty build
Post by: beemaman on April 05, 2013, 12:41:08 PM
good work phills these are the fiddly parts :) :)

keep them coming...
Title: Re: Phils 4thirty build
Post by: rudycob1 on April 05, 2013, 12:48:20 PM
Glad to see you back working on it.
 :)
Title: Re: Phils 4thirty build
Post by: Phils99 on April 05, 2013, 01:43:49 PM
Cheers for the comments guys!

More updates for you......

Decided to drag the back end off the car and onto the drive to have a go at cutting out the holes.

started hacking at the the rear grill area....essential tool of the trade an air saw...just wish I had a bigger compressor...I get about 1-2 inches along and it runs out! took ages to cut this out!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2018/20130401_121144_zps843ec869.jpg)

Another essential tool the black and decker power file!!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2018/20130401_121207_zps4ff89262.jpg)

rear grill area cut out....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2018/20130401_172115_zps1b74409c.jpg)

Next to go was the fuel filler cap area.....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2018/20130401_121152_zps6d7b958a.jpg)

and then the tail lights....these took ages as the shape is not clearly defined on where you should cut out, so it was a case of cut and trial fit the lights until they fit nicely, this left them looking like this:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2018/20130401_172128_zps4592900c.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2018/20130401_172124_zpse7eae4f5.jpg)

I then only managed to do the lower air intake as I ran out of time!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2018/20130401_172142_zpsb7e66548.jpg)

more soon!!
Title: Re: Phils 4thirty build
Post by: NYAL F430 on April 05, 2013, 05:45:48 PM
hi phil, great to see you back, build looks like its coming along nicely, nice job cutting out the vents, how easy is it to cut out the vents along the bottom, need to make a start on mine soon.

thanks nyal

Title: Re: Phils 4thirty build
Post by: Phils99 on April 05, 2013, 07:26:14 PM
the lower and upper air intake vents are both "back trim" that is to say all you need to do is get yourself a black and decker power file (£40 from B&Q) and just let it do it magic until you "see light" through the fibreglass. Here is a pic from inside of the lower vent you should be able to see that its been filed down and not cut out!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2018/20130405_191832_zps5938be1d.jpg)
Title: Re: Phils 4thirty build
Post by: MADMAN on April 05, 2013, 10:30:43 PM
managed to get a little more time on her...decided to have a go at the petrol pipes...

You need to release this bracket as it holds the main filler pipe and the breather pipe..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2017/20130326_190812_zpsa0452948.jpg)

A similar bracket is underneath the car that holds the breather steady..didnt get any pics of this..

After removing the filler and pipes, I cut a length off the breather to use to help me attach the new supplied pipe with:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2017/1b53c593-3dd2-4d1c-958c-285fd13c887a_zps159234b5.jpg)

Which I then connected to my new pipe:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2017/20130331_190656_zps4d6e7314.jpg)

I then took a piece of rubber tubing I had a rivited it around the hole to stop the pipes scraping on the metal:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2017/20130331_193232_zpsee9d0c48.jpg)

The two pipes were then positioned until I was happy and pushed through the hole ready for the kit!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2017/20130331_202719_zpsfbad9a2e.jpg)

So thats another ticked off my very long list of jobs to do!

another update very soon
Things to do, buy a bigger compressor ;D, 14cfm about the biggest single fase will run happy I think, (anyone know any different) also I fit an earth wire to petrol filler neck, dont know if it needs it, thought it would be safer. keep up the good work Phill
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on April 05, 2013, 11:29:56 PM
Cheers Steve,
Yea I defo intend to fit earth onto neck when I install it!
Title: Re: Phils 4thirty build
Post by: Darren on April 06, 2013, 12:09:50 PM
I'm running 17cfm 4hp sinlge phase BUT this has it's own dedicated power to the consumer unit, if you're electrically minded a 230v digital inverter will run the cheaper 3 phase units that workshops chuck out. The chinese inverters are soooo cheap nowadays. When I started tooling up the workshop my only option was single phase equipment, now these inverters allow 3 phase at home, we run all our new automation equipment in 230v 3 phase, it's a lot more reliable and controllable, no hot starting and blown caps, all this is good news for high torque starting ie compressors, hydraulics etc...
 And before anyone points out, I know I could have powered up using the old 3phase converters, ughh  :)
Anyway back to topic...
 Nice detailed photo's Phil, keep up the good work. This'll be another 430 on the road before mine ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on April 06, 2013, 06:16:06 PM
I bet mine will be the last 430 built!!!

I have, due to the little time I get on the project, realistically  set my on the road date to be spring next year!
Title: Re: Phils 4thirty build
Post by: NYAL F430 on April 06, 2013, 06:54:11 PM
Phil, no worries me to,
have to repair my shed roof / due to the snow before any work on the old girl.

nice work keep going.
Title: Re: Phils 4thirty build
Post by: Phils99 on April 06, 2013, 11:14:27 PM
sorry to hear about your shed roof problems mate, luckily I think you said the car survived it, hope u get it sorted soon, then we will be building together mate!
Title: Re: Phils 4thirty build
Post by: Phils99 on April 08, 2013, 09:57:46 PM
just a quick update, having talked to Madman, he told me that I can convert my wheels from using wheel bolts to wheel nuts by buying "studs".

I got more info and the studs you need are M12 x 1.5, now I measured my existing rear studs and I worked out that I needed 60mm studs like these:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2019/20130408_183841_zpsad8f100a.jpg)

I then also purchased a bag of 20 wheels nuts of the following dimensions obviously M12 x 1.5 to match the studs!:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2019/m12ab_zps7d6ccb38.jpg)

These will fit the new front studs and the existing rear threads

When I installed the studs and fitted the wheel and the fake disc, I couldnt tighten the wheel up as the studs were too long.

I ended up cutting off 15mm off each stud leaving them as follows:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2019/20130408_193152_zpse41bf47a.jpg)

So that when I fitted the wheel on, they left this much thread available:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2019/20130408_193417_zps0382a6af.jpg)

So I guess you need 10 x M12 x 1.5 x 45mm studs for the front wheels.

Thats all for now, hope this helps someone....
Title: Re: Phils 4thirty build
Post by: Phils99 on April 08, 2013, 10:44:12 PM
Ive had a question about where I got the studs/nuts from, so I will post the ebay links here, these will obviously disappear after about 90 days or so, so click on them early!!

Studs, but remember, I would go for the 50mm ones, but you will still need to cut off 5mm or you may get away with it...

http://www.ebay.co.uk/itm/370476921274?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649 (http://www.ebay.co.uk/itm/370476921274?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649)

..and here are the wheel nuts

http://www.ebay.co.uk/itm/320781922802?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649 (http://www.ebay.co.uk/itm/320781922802?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649)
Title: Re: Phils 4thirty build
Post by: Darren on April 09, 2013, 07:53:49 PM
just an add on note, studs must be at least en8 rated, standard studding is not strong enough.
D
Title: Re: Phils 4thirty build
Post by: Phils99 on April 09, 2013, 09:47:02 PM
D
are you saying these studs are not good enough? These are sold as wheel studs????
Title: Re: Phils 4thirty build
Post by: Darren on April 10, 2013, 06:31:40 AM
They say high tensile, so should be fit for purpose, the ebayer doesn't say what grade they are, allen bolts are typically en8. Ask the seller what grade they are just incase.
D
Title: Re: Phils 4thirty build
Post by: Phils99 on April 13, 2013, 09:01:40 PM
update...

As the weather was lovely today, decided to push the car out of the garage and let the engine run up to temperature as it hasnt been run for a while...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2020/20130413_095548_zpsfa966a3b.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2020/20130413_095606_zpsb8fda7d5.jpg)

Did a little bit more cutting out of the rear end, this time it was the upper air intakes which are back trimmed with my black and decker power file..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2020/20130413_102654_zpsf6d79fdf.jpg)

after a face full of fibre glass dust, both sides now trimmed...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2020/20130413_105009_zps862b9544.jpg)

Marked up the back for the numberplate light cut outs...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2020/20130413_191326_zpsf37b23ea.jpg)

I kept a template of my number plate light cut outs from the MR2 so I stuck this on and draw round it, its now ready to cut out

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2020/20130413_192535_zpsb76559c9.jpg)

Got bored of cutting the fibre, so I moved onto moving the alarm siren from out of the frunk to underneath, first I seperated the alarm holder from the large metal bracket it is riveted to, I then drilled 2 holes in the frunk after I had worked out where it will fit nicely under the frunk. This was the best spot...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2020/20130413_172032_zps3cbd6583.jpg)

I then refit the siren into the bracket...All done..simples!!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2020/20130413_172226_zps3eb8249d.jpg)

While the car was out side, I decided to have another go at the reshaping of the front wheel arch to take the 19" wheels I have....this was loads of hammering....wheel on...check..wheel off...hammer...hub off...bigger hammer!...hub on...wheel on...check....phew I was Kn$%£$ed after this!!

more to come....
Title: Re: Phils 4thirty build
Post by: tenpin on April 13, 2013, 10:41:55 PM
When you're modifying the wheel arches (and checking with the wheels), don't forget to allow a little extra for the wheel arch liners...

 - tenpin
Title: Re: Phils 4thirty build
Post by: base on April 14, 2013, 01:27:39 AM
update...

As the weather was lovely today, decided to push the car out of the garage and let the engine run up to temperature as it hasnt been run for a while...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2020/20130413_095548_zpsfa966a3b.jpg) ]
That looks wicked!
Title: Re: Phils 4thirty build
Post by: Phils99 on April 14, 2013, 09:51:24 AM
cheers base...I thought so to, thats why I put the pic up!!

Even at this stage of the build, its looks awesome with the wheels on!
Title: Re: Phils 4thirty build
Post by: NYAL F430 on April 14, 2013, 10:53:40 AM
Ha, Phil got up this morning log in to DNA looking good with the wheels,like the stance.
Title: Re: Phils 4thirty build
Post by: sean doyle on April 14, 2013, 12:16:32 PM
Cheers for sharing them pictures your looks amazing keep up the good work  ;)
Title: Re: Phils 4thirty build
Post by: Phils99 on April 21, 2013, 10:00:06 AM
had another day on her today....managed to hammer in the passenger wheel arch for the 19" front wheels...bloody hard work!
I removed the full hub so I could get a good swing without damaging anything....anyway the wheels clear now!

Next I thought I would get a nice easy job out of the way and drill the door straps and put a bolt in them...what the hell are they made of? I have gone through about 4 HSS drills and they still wont go through!...spent 1 hour doing these until I gave up for now...need to get some very strong drills to get through these....

So, next job was to finish cutting out the number plate light slots in the rear end...at least this job went OK..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2021/20130420_161832_zpsf0c4bf53.jpg)

So thats the back end all cut out now, lets stick it on the car to give me space in the garage!!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2021/20130420_183652_zps4a919059.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2021/20130420_183640_zpsedbaeb04.jpg)

QUESTION TIME FOR ALL YOU EXPERTS....

1. Should these parts be touhing the body?, cos mine arent!
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2021/20130421_082824_zpse22bedfb.jpg)

2. This part only seems to touch the outer edges af the cross brace, is this correct?
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2021/20130421_082839_zps91514c57.jpg)

3. I think this piece should be cut here, but I see in no build threads or anywhere anyone actually detailing this!! Can someone confirm for me?
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2021/20130421_082901_zpsb7cf2297.jpg)

4. Am I supposed to trim this part so that it sits on the metal and not the plastic moulding?
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2021/20130421_082931_zpsf8456ed4.jpg)

5. Again, should this bit be trimmed here?
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2021/20130421_082944_zpsdbaefe60.jpg)

Please let me know the answers guys, as I dont want to tek screw it on until it sits right....

Thanks in advance
Title: Re: Phils 4thirty build
Post by: beemaman on April 21, 2013, 10:34:48 AM
Hi phill

As far as I can remember the pic number 1 does not touch the strut top

Pic 2 I'm sure it will only touch the two sides but bonds all along the brace

Pic 3 yes should be cut there buddy

Pic 4 and 5 mine was cut around the seal and I sealed the body to the black seal before painting

Hope this helps buddy and it will b in my build diary somewhere

May also b best to see what DNA say :) :)
Title: Re: Phils 4thirty build
Post by: Lord Beany on April 21, 2013, 12:39:30 PM
Looking good, glad you are making progress again.

That central brace, don't cut it out until you have bonded the kit and it as all dry. This piece will help keep the shape until bonding agent is dry. Rear quarters could droop outwards a little.

The area on the strut tops, DNA recommends just bonding as Beems says, they float above the metalwork. I didn't like that idea and actually bonded and Tec screwed mine down to the strut top. I have left two Tec screws in each. Doing this did not affect the alignment between the rear deck and rear wings at all.

The pic where the timber cut out sits on the rear cross member actually looks thicker where you have circled it. Maybe sanding down the underside on the end will let the rest sit down flush. Mine sat down on the cross brace nicely.

The area around the corner of the old roof rubber, I left as it is and bonded it in place which seals any gap between the body and that rubber. I don't think trimming will allow it to sit lower, just allow the lines to match.

Hope that helps.

Keep at it.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on May 19, 2013, 11:11:03 PM
hi guys, managed to get a day on the car today, I decided that I need to get the doors perfectly lined up with a little bit of altering of the panels so that they sit perfect into the door shape as shown:

Drivers door

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2022/20130519_131532_zpsf40b7bd5.jpg)

Passenger door

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2022/20130519_163421_zpsbbfdbc61.jpg)

So Im happy with these now, so lets line the rear end to the doors....

Drivers side fit lovely...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2022/20130519_163521_zps317c5fbf.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2022/20130519_163536_zps6db84033.jpg)

But after about 2 hours of slightly repositioning the rear end, I think I may have something wrong with the passenger door, if I position the rear end so it sits snug with the MR2 like this....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2022/20130519_163353_zpsbc2d9950.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2022/20130519_163402_zps346400f3.jpg)

Then the passenger door sticks out at least 10mm from the rear end like this!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2022/20130519_163435_zps8962fa52.jpg)

The weirdest thing is that all of my panels are "white", but just this door and only this door is a grey colour.....do I have a wrong door?

Im not sure what to do next without dramatically sanding down the door to fit! as no way will a body shop make up 10mm I would think!
The only way I can see that this will fit it to remove 10mm from the door depth!!
Anyone else have this problem?
Title: Re: Phils 4thirty build
Post by: rudycob1 on May 19, 2013, 11:20:21 PM
Just a thought. Is your door striker plate in the right place.
From memory if this moves the door alignment in and out will alter.
Worth checking.
Title: Re: Phils 4thirty build
Post by: Phils99 on May 20, 2013, 08:11:31 AM
yea...I checked that Rudy, the door cant possible close any tighter, its as it was and opens and closes perfectly
Title: Re: Phils 4thirty build
Post by: Paul79 on May 20, 2013, 09:31:55 AM
sorry to hear what's happened. have you compared the thickness of both door skins side by side Phil? or measures the depth of them to see if they are different?
Title: Re: Phils 4thirty build
Post by: Phils99 on May 20, 2013, 11:45:38 AM
DNA FANTASTIC CUSTOMER SERVICE STRIKES AGAIN!!!

Just been on with Roland, and he solved my "door sticking out 10mm" issue!

I didn't notice that the door has solid rubber stops which push the door out and puts the pressure on the latch to stop the door rattling, under advice from Roland and after lots of measuring, I removed these and the door is now within a few mm of being flush with the rear quarter, so this is now acceptable!m I can trim the rubber stops later to stop any rattling.

here are the offending rubber stops and where they live for anyone else who has this issue:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2022/20130520_111741_zps379f8d43.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2022/20130519_163421_2_zpsde171116.jpg)

Many many thanks again DNA!!
Title: Re: Phils 4thirty build
Post by: Paul79 on May 20, 2013, 12:19:27 PM
great stuff... that is going on my to do list right now!!!! does your other door have them?
Title: Re: Phils 4thirty build
Post by: Phils99 on May 20, 2013, 01:53:53 PM
it does...but strangely the drivers door fit without a problem!!
Title: Re: Phils 4thirty build
Post by: dman1409 on May 21, 2013, 10:10:55 PM
Hey phil!

Great to see this kit is working for you!!! great work so far!!

Are you still going to use the original exhaust you have bought for your extreme kit??

keep up the good works!! she is looking great!!

Cheers!
Title: Re: Phils 4thirty build
Post by: Phils99 on May 21, 2013, 11:40:56 PM
thanks for the comments dman, and no, I sold the original 430 exhaust I had with the extreme kit...
Title: Re: Phils 4thirty build
Post by: ghall164 on May 22, 2013, 02:43:42 PM
Coming together nicely now mate easier than the extreme kit  :)
Title: Re: Phils 4thirty build
Post by: Phils99 on May 22, 2013, 02:52:01 PM
jeez!! I would say so!! but the best part is the customer service as shown above in this post...what a briliant company DNA are, from what I have seen on here and Mad Mechanics, they must be the number 1 kit car company IN THE WORLD!!
Title: Re: Phils 4thirty build
Post by: MADMAN on May 22, 2013, 11:18:14 PM
jeez!! I would say so!! but the best part is the customer service as shown above in this post...what a briliant company DNA are, from what I have seen on here and Mad Mechanics, they must be the number 1 kit car company IN THE WORLD!!
            I,ll definatly second that
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on May 28, 2013, 01:10:10 PM
just a very quick update...

on Saturday I juggled with the rear end/doors/front clip line up until I was happy, it will still need a little work, but Im hoping the body shop will take care of that! As Roland has said, do worry too much about the gaps etc as long at they are just a few mm out, that can be sorted by the body shop...I hope!!

Anyway, when I was eventually happy, I decided IT WAS NOW TIME......yes...its time to bond!
This was worrying as I havent done anything remotely like this before!!

So, I removed the door panel, etched the ferrari panel and the MR2 door and primed them.

I then took the tube of Betaseal I had and was totally confused! these types of tubes I have used before have a rear disc that is pushed in by the gun, these ones have what seems to be a complete seal around the bottom! what??? AND they have something inside that rattles?????????

Anyway, after MUCH deliberation, I decided that the gun would probably brake the disk out of the bottom of the gun enabling you to use it....so....with one eye closed, I inserted the tube into the gun and squeezed, and squeezed and them "POP" the disc on the bottom seperated as I had hoped!.....so, inside was a little plastic holder full of beads, which I assume are to absorb moisture??
So I threw those away, slotted it back in the gun, popped a hole for the nozzle and thought "here we go..."

BUT, MY GOD, is this stuff thick! I had a really cheap plastic gun and it was impossible to use, so I shot out to B&Q and bought the "heavy Duty" gun which is metal and much better.

It was still very tough to squeeze this stuff out, but I managed to do both doors and rescrew them back in place.

Its unbelievable just how much I dont know about these things and laughable really when you hear/find the solution, its so simple...give me a massive computer to build and configure any day! (thats my day job!!)

So, I then put her to bed and next weekend I will have a go at the rear end....which I think will be a nightmare, because you have to put the Betaseal all over where the rear end touches and then try to ease it back on without making a mess....Im expecting a bit mess!!

I have just a couple of pics of the panels primed and will probably put these up later....

more to come!!
Title: Re: Phils 4thirty build
Post by: MADMAN on May 28, 2013, 03:12:53 PM
Put your betaseal tubes.in a plastic bag then in hot water it should make it more fluid
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: rudycob1 on May 28, 2013, 07:31:30 PM
Yes it's thick stuff. I put mine in front of a heater for a while and it did help but it's thick messy stuff.
Use disposable gloves mate, well worth it.
Title: Re: Phils 4thirty build
Post by: Nik the Greek on May 28, 2013, 11:53:29 PM
A small parenthesis from me.i'm new to this club,so i have missed some posts.
I have allready read all the 11 pages.Speechless.splendid work.Keep going.
I see your post and i'm thinking myself.I visualize the day that i will writting about my own 4thirty.
Gongrats.Waiting for more photos.
Title: Re: Phils 4thirty build
Post by: Phils99 on May 29, 2013, 09:04:33 AM
hey Nik!

Thanks for the comments.

We have all been there mate, I sold everthing I had and saved and saved for the day, its hard parting with the thousands of pounds for a load of panels and parts, but I can tell you...WORTH EVERY PENNY...you get just about every piece you need minus a few nuts and bolts and trimmings (NOWHERE ELSE will you get that when you buy a kit!!) and the support from DNA and all on this forum just leaves me speechless, forum members will pop round to your house ( if you live nearby...but in your case, we will all pop over to help you for 2 weeks!!  :)  :) ), they will offer telephone advice, lend tools/equipment...everything, its an amazing "club" the DNA club and I for one am proud to be a part of it and would recommend it to any would be car builders.

As you have seen, Brian from DNA is over in India building a car, Im sure he would come to Greece to build yours!!

Keep saving mate and hurry up and join the club!
Title: Re: Phils 4thirty build
Post by: MADMAN on May 29, 2013, 10:22:42 AM
hey Nik!

Thanks for the comments.

We have all been there mate, I sold everthing I had and saved and saved for the day, its hard parting with the thousands of pounds for a load of panels and parts, but I can tell you...WORTH EVERY PENNY...you get just about every piece you need minus a few nuts and bolts and trimmings (NOWHERE ELSE will you get that when you buy a kit!!) and the support from DNA and all on this forum just leaves me speechless, forum members will pop round to your house ( if you live nearby...but in your case, we will all pop over to help you for 2 weeks!!  :)  :) ), they will offer telephone advice, lend tools/equipment...everything, its an amazing "club" the DNA club and I for one am proud to be a part of it and would recommend it to any would be car builders.

As you have seen, Brian from DNA is over in India building a car, Im sure he would come to Greece to build yours!!

Keep saving mate and hurry up and join the club!
Hey Phil, leave Brian in India I,ll volunteer for the Greek build, it will probably take me all summer to finish ;D, I,m looking to book first two weeks in July just for a reky ;) ;) on the other hand if it,s winter then send Brian ;)
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Nik the Greek on May 29, 2013, 01:25:54 PM
I really don't know what to reply to you both (Phils99 and Madman).
I'm very happy to be a part of this forum.To be true,i didn't expect such a welcome for many reasons,
and first of all the fact that i don't have the car yet.
But your words make me very happy and give me the strength to wait for the right moment.And then,beleive me,
i will call you all here in Greece and when the project finish,we will make a tour.
Hey Phil, leave Brian in India I,ll volunteer for the Greek build, it will probably take me all summer to finish ;D, I,m looking to book first two weeks in July just for a reky ;) ;) on the other hand if it,s winter then send Brian ;)
MADMAN 8)
Don't care if it's winter.We have many nice ski resorts for any winter sport you like.If you are not a fun of this,then we will be in front of the fireplace all day drinking '' Rakomelo ''.A very nice Greek drink.

P.S. Really sorry for messing with the post.(this post is for another reason,not for me).
And something more.Plssss upload more photos.because of the fact that i cann't have it now,i want see it all the time.
Title: Re: Phils 4thirty build
Post by: Paul79 on May 29, 2013, 09:50:11 PM
Plenty more photos to come Nik! Check out Rudy's build thread and mine (paul's 4thirty build diary). Things are about to get exciting on mine as I pick my kit up on 7th June. Haven't been able to do much for a few weeks on car as waiting for kit to be ready. But spent that time reading up, and getting organised so it is as smooth as possible. Phil is exactly right about the club. It feels like a family.
Title: Re: Phils 4thirty build
Post by: Nik the Greek on May 31, 2013, 09:12:15 AM
It feels like a family.
I feel like that allready.Thanks for that.
Ok keep going with the project Phil.
Title: Re: Phils 4thirty build
Post by: Phils99 on May 31, 2013, 09:38:18 AM
Just a couple of pics to keep Nik the Greek happy  :)

Here is the door etched and primed:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2023/20130525_154311_zps6b2f823c.jpg)

and here is the door panel ready for the Betaseal...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2023/20130525_154250_zpsa8213c9f.jpg)

Thats all I got at this time!!
Title: Re: Phils 4thirty build
Post by: Nik the Greek on May 31, 2013, 09:59:51 AM
Thanks Phil.I'm allready happy.You don't have to try hard. ;D ;D ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on June 03, 2013, 10:06:59 PM
had some time tonight, so I thought I would have a quick go at the petrol flap....

here is the flap next to the carrier supplied with the kit..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2024/20130531_170748_zps7a2444f0.jpg)

Now, I wasnt sure if you cut the Mondeo flap to fit the carrier, or cut the carrier to fit the flap, so I watched the build DVD and flicked through a few build threads, and it looks like the answer is that you cut the flap to fit the carrier...

Here is the flap cut ready...
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2024/20130531_194859_zps62847457.jpg)

test fit the flap into the carrier, it does need to be pushed in, but I intend to clamp it when bonding...
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2024/20130531_194955_zpscaa7cdcc.jpg)

applying the "sticky stuff" into the carrier...
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2024/20130531_195355_zpsc9fddbeb.jpg)

And then inserting the flap into the carrier, pushing it down, and then clamping it in place until the Betaseal goes off..
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2024/20130531_195512_zps8a534a3c.jpg)

Job done!!

Next job is to bond on rear end, but I just need to adjust it slightly at the drivers door side as I am not happy with the gap.
I also need my misses here to help me lift it on and off and she is away next weekend, then I am at Newark the weekend after, so its gunna be a while until I get chance to do the rear end bond!..ah well...no rush!
Title: Re: Phils 4thirty build
Post by: rudycob1 on June 03, 2013, 10:52:08 PM
Nice work.
Good to see you getting more jobs done.
You will have it in a spray shop soon.
Keep up the good progress.
Title: Re: Phils 4thirty build
Post by: Phils99 on June 04, 2013, 07:13:07 AM
cheers rudy,
seems to be taking ages due to the fact that I only get a day free every now and then...you will be driving yours around very soon!
Title: Re: Phils 4thirty build
Post by: kalifornia on June 04, 2013, 08:51:40 AM
Keep the excellent documentation and pictures coming as it will help many people in the future.
Title: Re: Phils 4thirty build
Post by: Paul79 on June 04, 2013, 09:51:44 AM
hear, hear... it is helping me already!!!  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on June 04, 2013, 02:30:23 PM
Cheers guys,

If only one of my pictures helps someone to figure the "non" obvious stuff I will be happy!!

I know how us "non car builders" can struggle with what would seem the simplest of things to the experts!
Title: Re: Phils 4thirty build
Post by: seriph on June 04, 2013, 11:30:10 PM
For folks who have already completed one vehicle and have the stamina to do more, subsequent builds must get far easier.

Man, I would love the chance to work on one!
Title: Re: Phils 4thirty build
Post by: Phils99 on June 05, 2013, 08:37:34 AM
Seriph, you can! just buy one! :-)

Where are you based?
Title: Re: Phils 4thirty build
Post by: seriph on June 05, 2013, 08:45:36 AM
Australia  -  sure I can build one - it would just never get approved for registration therefore uninsurable
Title: Re: Phils 4thirty build
Post by: kalifornia on June 05, 2013, 08:51:08 AM
i've been to sydney a few times now, really loved it. I'll look you up if I ever visit your neck of the woods
Title: Re: Phils 4thirty build
Post by: seriph on June 05, 2013, 09:08:21 AM
No worries mate - we are near Melbourne.
Title: Re: Phils 4thirty build
Post by: dman1409 on June 10, 2013, 09:02:52 PM
Hey phill !

I see you are making good progress!! Looks nice and clean!! Can't wait to see more!!
Cheers!!
Title: Re: Phils 4thirty build
Post by: Phils99 on June 10, 2013, 10:08:55 PM
Newark this weekend, then I hope to get some time the weekend after!!
Title: Re: Phils 4thirty build
Post by: ghall164 on June 23, 2013, 10:48:14 AM
Keep at it buddy it's going to be great and thanks for all the photos a picture tells a thousand words invaluable to later builders cheers :D
Title: Re: Phils 4thirty build
Post by: Phils99 on June 24, 2013, 02:20:18 PM
So, today (Sunday) was going to be the "bond the rear end on" day...but unfortunately, the weather took a turn for the worst and I was unable to get this done.....

I did manage to drill out the large hold under the sill so that I could use bolts to mount the wing with before I had to put everything back in the garage....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2025/20130617_191320_zpsf8bedec3.jpg)

It then started to rain badly so I started pottering about and decided to put the catch into the fuel filler holder which I had bonded previously.

Here you can see the part that needs cutting out:
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2025/20130623_125353_zpscc5ffc8a.jpg)

I started by drilling 2 holes and then filing it out:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2025/20130623_125542_zps18328641.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2025/20130623_125728_zps1747ca72.jpg)

So its now the same shape as the hole for the catch....
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2025/20130623_130156_zpscd039a39.jpg)

but it needs to be bigger so that you can twist the catch when fitted....out with the Dremel!!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2025/20130623_131429_zps0cbaf8f6.jpg)

Test fit the catch and it fits great!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2025/20130623_132015_zpsb6057280.jpg)

So now I just drilled a few holes in the top to aid when I bond the cap on.

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2025/20130623_132624_zps9c01ea3f.jpg)

And that was it really, I decided to take the wife out shopping instead and I will hope for better weather next weekend....
Title: Re: Phils 4thirty build
Post by: Paul79 on June 24, 2013, 03:50:00 PM
Phil, on the fuel filler cap, did you have to make the circumference of the mondeo cap smaller for it to fit nicely in the dna housing? i have trimmed back excess at the bottom of the mondeo piece so it sits flush in the dna housing however  it seems the rubber edge on the mondeo cap does not sit down flush with the housing at 12 and 6 o'clock if you know what i mean... the dna housing is more of a cone shape and opposed to a cyclindrical shape if that make sense...
Title: Re: Phils 4thirty build
Post by: Phils99 on June 24, 2013, 04:14:00 PM
yes, I know what you mean, but what I did was, after trimming the bottom of the Mondeo flap, I forced it into the DNA housing so that the edge (I removed the rubber as it shows in the DNA video) was lower than the DNA housing.
Look at my first pic of the cap below.

What this did is make the edges of the part of the flap which locks to the catch just catch slightly on the mondeo housing, so I just filed these down a little and it fits in nicely!
Title: Re: Phils 4thirty build
Post by: rudycob1 on June 24, 2013, 05:35:43 PM
Nice work Phil.
Hope the weather will be could for you next weekend.  :)
Title: Re: Phils 4thirty build
Post by: beemaman on June 24, 2013, 09:47:32 PM
Looking good phil

Bet you can't wait to bond it all on and then start the fine details

Any info needed don't forget to drop me a mail :)
Title: Re: Phils 4thirty build
Post by: Phils99 on June 24, 2013, 10:48:09 PM
cheers for the comments guys!!

yea, cant wait to get the rear and front end bonded, then it gets interesting fitting the bonnet, rear deck, lights etc.....
Title: Re: Phils 4thirty build
Post by: Phils99 on July 01, 2013, 11:21:21 AM
OK good weather at last!!!

Managed to get to work on her on Sunday so I have done the following:

1. Etched and primed the rear end and the contact areas of the car
2. Applied the Betaseal to all of the areas to be bonded EXCEPT the sills
3. Put the back end on, lined it up and tek screwed it in place
4. applied Betaseal to the sills and bonded those on
5. banged in the front inner arches some more
6. wired up a trickle changer connection which will be accessible from a hole in the rear behind the number plate when done

The reason I betasealed the sills after the rear end was to aid in the fitting of it without all the black stuff being messed up by the flapping sills (advice from Madman! cheers!!)

Banging in these inner arches are a PAIN, I seem to be stuck on a seam that just doesn't want to go in any further. I then noticed that the profile on my rear tyres is 30 and the profile on my front tyres is 35????

Is this correct? what are you guys running on the fronts? I would have though the profile would be the same for all 4 tyres?

Also, noticed that my sill on the passenger side is much closer to the tyre than the drivers side, so I measured from the rear to the front of the sill on each side and the passenger one is longer by just over 10mm!!

Im not sure how this will affect the front clip as I may have to remove this 10mm to get the door gap between the front of door and the wing correct, the door gap at rear of door is fine.

Anyway, a couple of pics, not much to show as when bonded it looks no different than when it isnt bonded!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2026/20130630_121453_zps4791230e.jpg)

I also had to pack out the passenger side as, when the door is shut, the door stuck out about 5mm from the rear end and you cannot adjust the door locking posts.

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2026/20130630_121459_zps1ce5db49.jpg)

I have also bonded around these bits....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2026/20130630_125226_zpse4105f27.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2026/20130630_125213_zps9650ae93.jpg)
Title: Re: Phils 4thirty build
Post by: Paul79 on July 01, 2013, 12:35:04 PM
looks great matey. i think the profile on my tyres is different front and back, but the width of the tyres (as if looking at them on the car from the back of the car) is bigger on the rears. not sure whether this is correct or not. i would expect to have wider tyres on the rear of the car that the front, although looking at the many pictures if have downloaded of completed dna 4thirty's, i noticed a lot seem to have the same profile front and back. i could be wrong as this is only from looking at a photo.
Title: Re: Phils 4thirty build
Post by: Phils99 on July 01, 2013, 01:15:41 PM
Cheers Paul, to be honest, its only 5% different so it isnt that noticeable, I just wondered if it was correct.
Looking on t'interweb, the real F430 has 35 front and rear!
Title: Re: Phils 4thirty build
Post by: seriph on July 01, 2013, 02:54:12 PM
What are the tyres' full specs please?
Title: Re: Phils 4thirty build
Post by: Phils99 on July 01, 2013, 03:10:41 PM
My fronts are 235/35 ZR19
My rears are 265/30 ZR19
Title: Re: Phils 4thirty build
Post by: Lord Beany on July 01, 2013, 05:40:22 PM
I think i'm running:

225/35 zr19 fronts
245/30 zr19 rears

Different design wheels that dna have used over the years have resulted in different tyre widths being used.

Typically:
360 is on 18's
430 is on 19's
Scudo on 19's
DN8 on 20's

Beany ;D
Title: Re: Phils 4thirty build
Post by: Darren on July 01, 2013, 06:02:28 PM
V8 DNA 430 20"  ;D
Title: Re: Phils 4thirty build
Post by: seriph on July 02, 2013, 04:38:14 AM
Thanks mate.

Trying to get my brain around this. I recall an issue with my speedo's accuracy back when I built my 93 Porsche turbo rep and stuck it on 18s.

Please confirm or correct:


So the wall heights of those tyres would be:

68.75 mm front and;
73.5mm rear

I guess doubling the rear wall hieght then adding the wheel diameter gives an overall rolling diameter to measure against what an MR2 speedo would be expecting.... Or at least to compare the standard wheel's diameter.
Title: Re: Phils 4thirty build
Post by: Paul79 on July 03, 2013, 10:11:03 PM
Phil, I've just had a look at what I've got from DNA, wheel wise:

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

I guess with my fronts being thinner the arch rub is not going to be so bad. Will find out tomorrow night when i fit them!  ;D. Yours are much wider front and back and your design is much different to mine.  Just curious, did you specify this type of wheel from DNA? Picture of mine attached

Cheers
Paulie

(http://i1315.photobucket.com/albums/t597/pjlucas1/IMG_6084_zpsc3d48978.jpg) (http://s1315.photobucket.com/user/pjlucas1/media/IMG_6084_zpsc3d48978.jpg.html)
Title: Re: Phils 4thirty build
Post by: Phils99 on July 03, 2013, 11:48:20 PM
mine were a bunch of second hand wheels and tyres that dna had as I didnt like the one they were supplying at the time...they are the same as madmans if you look at pics of his.
Title: Re: Phils 4thirty build
Post by: Paul79 on July 04, 2013, 07:05:54 AM
yeah i thought they looked familar
cheers
Title: Re: Phils 4thirty build
Post by: Lord Beany on July 06, 2013, 09:36:03 AM
Seriph,

The Ferrari style replacement gauge front I got from DNA for my car, has the Speedo numbers spaced slightly differently to account for the larger diameter wheels/tyres. It is accurate and reads the same as my GPS at all speeds. ;D

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on July 06, 2013, 09:18:34 PM
Had a few hours on her today and it just all went so well!

Firstly I managed to get the front clip in place and lined up so that I was happy with it.

Next, I thought I would refit the exhaust which gave me loads of trouble before and it just all went together perfectly!!
So I also had a very little play with the rear frame.

Anyway, some pics.....

First the front wing on the drivers side

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2027/7761148a-901d-47f6-a983-a871a4e09f43_zps15c6ed83.jpg)

Same thing but passenger side

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2027/20130706_174952_zps993435aa.jpg)

I really wanted to bond this on, but I still have those pesky wheel arches to beat in! Im going to get a larger hammer tomorrow, so may get them done soon!

Here are the exhaust tips from the rear, I know not exactly lined up, but that will be done when I get some exhaust sealant as I didnt have any!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2027/20130706_182635_zps39e3c126.jpg)

I couldnt find many detailed pics of the exhaust fittings on the forum, so here is how mine went together, I know some people have done it slightly different, but really, its how it works for you so just fit it the best for your supplied exhaust

Here is the main silencer ("silencer" LOL!!) this mounts to the existing upper left hand mount using the U clamp with the shorter thread of the two U clamps with the thread welded on, this also requires another U clamp fitting yet for the left hand pipe:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2027/20130706_182647_zpsf2919f58.jpg)

This is how I mounted the right hand side, again using the existing upper mount and the longer of the two U clamps with the thread welded on (the thread is behind the metal frame), this also requires another U clamp fitting for the right hand pipe:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2027/20130706_182704_zpsfb13b618.jpg)

This pic shows the right hand side lower U bend fitted and the exhaust tips (covered in bubble wrap!) its a bit hard to see, but the U bend is secured in place using an existing nut from the rear bumper bar (the bar you cut shorter when preparing the car) and mounting one of the "allen key" shaped parts with the "polo mint" welded to it, a rubber mount and the U clamp with an "allen key" shaped piece of metal welded to it:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2027/20130706_182713_zps13ec607b.jpg)

Here is the left hand U bend, you can see the "allen key" shaped pieces that go into the rubber mount:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2027/20130706_182755_zpsb0ba8f35.jpg)

I then had a little play with the rear frame, but as usual for me, I didnt have any nuts and bolts to mount it to the car with, so I will do this another day. I laid the rear deck onto the frame as its been standing up in my garage for ages, so hopefully it hasnt gone out of shape!!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2027/20130706_193248_zpsac0c0b64.jpg)

I then had to lay the bonnet on just to see what she looked like!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2027/20130706_193301_zpsa8e47c34.jpg)

She is defo starting to take shape now and it was an enjoyable day now that im starting to get past bonding the rear end on, which was very worrying for me!!
Title: Re: Phils 4thirty build
Post by: seriph on July 06, 2013, 10:16:12 PM
So nice to see these details of your build mate.


Title: Re: Phils 4thirty build
Post by: Phils99 on July 06, 2013, 10:24:55 PM
Glad you like them Seriph!!
Title: Re: Phils 4thirty build
Post by: rudycob1 on July 06, 2013, 10:32:17 PM
Looking good mate. You will have her in the bodyshop soon  :)
Title: Re: Phils 4thirty build
Post by: Paul79 on July 06, 2013, 10:52:09 PM
well done matey. you'll be knocking on B&Q's door tomorrow morning for their extra extra large sledge hammer. just remember it doesn't open till 10am... although if you're a regular DIY'er like me, they let you sneak in early!  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on July 06, 2013, 11:22:27 PM
cheers guys!
Im hitting a car boot sale tomorrow so hopefully get everything I need there!
Title: Re: Phils 4thirty build
Post by: seriph on July 07, 2013, 02:27:48 AM
Seriph,

The Ferrari style replacement gauge front I got from DNA for my car, has the Speedo numbers spaced slightly differently to account for the larger diameter wheels/tyres. It is accurate and reads the same as my GPS at all speeds. ;D

Beany ;D

that's "doing it like you mean it"   -   these guys are great
Title: Re: Phils 4thirty build
Post by: Darren on July 07, 2013, 09:06:25 AM
Hi Phil, I'm not sure if the photo regarding the exhaust tips is at a wide angle but, if you want to mimic the Ferrari style exit the tips follow the sweeping line of the panel.
 I posted pictures etc on my thread
http://www.dnaoc.co.uk/index.php/topic,415.195.html
Obviously just an option.
D
Title: Re: Phils 4thirty build
Post by: Phils99 on July 07, 2013, 12:21:39 PM
great pics you have there Dangerous thanks! ....but they are later on in your build to be found on this link for those who want to see them:

http://www.dnaoc.co.uk/index.php/topic,415.msg16588.html#msg16588 (http://www.dnaoc.co.uk/index.php/topic,415.msg16588.html#msg16588)

As I said, the final line up will be done when I get exhaust sealant and yes, I want them exactly as a real one has them.
Title: Re: Phils 4thirty build
Post by: Phils99 on July 14, 2013, 11:05:11 PM
In between my birthday celebrations, days out at the seaside, family sunday lunch and beers in the garden afterwards, I managed to get a bit done on the car!

I managed to get the wheels off and give the inner wings a good whack with my new sledge hammer! they went in much easier with the right tool for the job! this is a pic of my before hammer and the new sledge hammer!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2028/20130713_163839_zpsf5f400bb.jpg)

So inner wings now done (no pics as nothing to see really!) so wheels back on and no rubbing on full lock!

I then thought I would have a go at the rear frame, so first I sorted out the hinges and which side they go on..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2028/20130712_182858_zpsca7683df.jpg)

I then mounted these onto the frame.....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2028/20130712_183322_zps94fd1c26.jpg)

and the other side

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2028/20130712_183715_zpsc32ff562.jpg)

...and then laughed when I tried to fit the frame on, as the length of the bolt sticking out stops it from closing! DOH!, so I reversed the bolts so that the head was at the hinge end...

Next was to fit the adjustable stops into the pre drilled holes in the frame....the first one I fitted ended up being distorted so I removed it and looked closely and it has a little locating lug as shown here...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2028/20130712_184557_zpsbee99421.jpg)

So I removed this with a stanley knife....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2028/20130712_184647_zps6718baac.jpg)

They then fit nicely into the holes....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2028/20130712_190333_zpsb5b5064a.jpg)

Next was to fit the lugs for the frame latches, the predrilled holes for these are too small and need enlarging...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2028/20130712_190348_zpsf3159247.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2028/20130712_191016_zps5b8e5013.jpg)

I then fitted the frame to the car using the spacers provied in the kit....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2028/20130714_185136_zpsc53c581c.jpg)

These were secured with the nut underneath, but the nut was pulling the small washer into the fibre glass, so I removed it and fitted these large washers to spread the load...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2028/20130714_185155_zpsdc3d535c.jpg)

Next it was onto the gas rams....having looked at other builds and also the build video, I drilled a hole in the car frame and mounted the ram, when I connected it up, I found that the pressure in the ram was bending the metal frame, so again, I removed this and refitted with a large washer at both sides, this made it much stronger!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2028/20130714_182724_zpse1fc9e76.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2028/20130714_183322_zpsb209f682.jpg)

The other end of the rams go into the pre-drilled holes in the frame...as per the video, I then clicked on the catches and lowered the frame to see where to fit them, these were then bolted into place...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2028/20130714_195938_zpsdc75771c.jpg)

As per a few builds on here, I then installed my "emergency" catch pulls to be behind the number plate, I havent connected the end to the latches yet....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2028/20130714_195924_zps0e3fa0fc.jpg)

and that was it for now! more next time....
Title: Re: Phils 4thirty build
Post by: Phils99 on July 15, 2013, 09:26:14 PM
Had a bit of time tonight, so I thought I would have a go at bonding the door handles.

I have never used this stuff before so this should be fun!

Firstly I keyed the surfaces of the handle and the hinge

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2029/20130715_182825_zps5f18595e.jpg)

I then mixed up the stuff...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2029/20130715_182750_zps97fa6651.jpg)

I then bonded the handles on and taped them on until they dry...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2029/20130715_182758_zps02139635.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2029/20130715_183012_zpsc6d95dba.jpg)

I thought I would have a look at the frame that holds the roll hoops, as, when I was trial fitting the rear deck, I noticed it seemed to have a slight curve on it, so I took a spirit level and laid it on the metal as so:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2029/20130715_183922_zpsb42a99d4.jpg)

As you can maybe see, the metal is not straight, as a gap appears at the right hand edge here....this is a closer picture...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2029/20130715_183955_zps4428ce5b.jpg)

Im just wondering if any of you current builder can have a look at yours to see if it is also curved or if DNA know if it should be?

Next session, I will drill and hard fix the handles and also look at fitting/bonding the petrol flap.
Title: Re: Phils 4thirty build
Post by: Paul79 on July 15, 2013, 09:40:53 PM
Hi matey, i'm not going to see the car for a bit but when i do, i will def have a look. might be 2 weeks though.. hopefully you'll have an answer by then anyway...cheers.. Paul
Title: Re: Phils 4thirty build
Post by: Phils99 on July 22, 2013, 11:17:35 AM
little bit of time over the weekend so, firstly, I drilled through the door handles so that I could "hard" fix them, I decided to use pop rivets on these...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2030/20130719_183108_zpsef470e00.jpg)

I then sanded back the excess P40...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2030/20130719_183552_zps21217d32.jpg)

and clipped it back on, I also fitted the solderless nipple and the wire so that it now works!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2030/20130719_191101_zps6882acd3.jpg)

I manages to find these "brake adjusters" on the bay so I am using them for the rear frame release pulls, I will fit 2, one for the emergency pulls behind the number plate and one for the main pull..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2030/20130719_191149_zps2ccd7119.jpg)

Here is the first one fitted...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2030/20130719_191921_zps083bf929.jpg)

and here is the cable running up from behind the number plate to the adjuster...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2030/20130719_191935_zps755ee791.jpg)

and this is the cable through the adjuster and round the catch...wish I bought some more solderless nipples! as you will need 6, 2 for the doors, 2 for the main rear deck release and 2 for the emergency release....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2030/20130719_192021_zps5ddbf509.jpg)

Title: Re: Phils 4thirty build
Post by: Paul79 on July 22, 2013, 11:28:52 AM
Nice work matey... Getting there.... 8) - like those brake adjusters - will nick that one if you don't mind!
Title: Re: Phils 4thirty build
Post by: rudycob1 on July 22, 2013, 12:23:04 PM
Looking good Phil.
Just a point on the rear release.
I have found that with the two cables the spring on the release is not man enough to return fully and sometimes gets stuck.
I added an additional spring to give it a bit of help and now works great every time.
Also make sure you have all the cables fitted before you bond the side pods in as otherwise it will be a nightmare trying to get the cables through. Point to keep in mind for later on.
Title: Re: Phils 4thirty build
Post by: Phils99 on July 22, 2013, 01:50:21 PM
Use what you like Paul, thats the whole idea of me posting this what seems to be simple obvious stuff to the seasoned builder, but becomes a "oh yea! I like that idea" to us!

Cheers Rudy, Ill have to see how that spring works when I get the second cable on!

..and yes...side pods will be last and I will make sure they have room!
Title: Re: Phils 4thirty build
Post by: MADMAN on July 22, 2013, 03:09:45 PM
Phill I used the oem pull lever on floor by adding another lever alongside the oem one, and used a longer cable for n/ side so you can open both latches without having to walk round car
MADMAN
Title: Re: Phils 4thirty build
Post by: Phils99 on July 22, 2013, 03:49:37 PM
great idea!

Im toying between original ferrari pulls and solenoids....I am going to have a play with solenoids I think! I know they have to be strong, but lets see what happens!
Title: Re: Phils 4thirty build
Post by: DNA AUTOMOTIVE on July 22, 2013, 04:37:58 PM
forget the solenoids been their tried and failed
call us will explain a couple of points
Title: Re: Phils 4thirty build
Post by: Nik the Greek on July 23, 2013, 10:46:38 AM
Nice Phil.Keep going.
Title: Re: Phils 4thirty build
Post by: Phils99 on July 23, 2013, 11:16:11 AM
had a go at mounting the pods onto the frame last night...here is the step by step...

First, mount the bracket that has the welded threads on to the frame..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2031/20130722_180824_zps9153fa98.jpg)

then, bolt on the similar shaped bracket without the threads to the previous bracket...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2031/20130722_181253_zpsbb83c061.jpg)

Now bolt on the adjustable spring hinge to this bracket using the holes that line up...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2031/20130722_182244_zps488ca54b.jpg)

Now I closed the frame, laid the pod somewhere near and then marked the holes in the spring hinge onto the pod itself, I then drilled through these and bolted the pod to the hinge.

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2031/20130722_183905_zps5980f5c2.jpg)

I then closed the frame again just to check its somewhere near...it doesnt need to be exact at this time as, using the brackets and the adjustable hinge, you have plenty of adjustment for when I have lined up the rollhoop part later.

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2031/20130722_184124_zps8fd4e2f0.jpg)

I then bolted on the catch for when the pod is "retracted" to have the roof on....testing this, it wont latch at this time as I will need to remove some of the pod (the bit you can see sticking out above the hinge, but I will do this after I have lined everything up later...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2031/20130722_184604_zps02118634.jpg)

I then did the other side the same....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2031/20130722_190420_zps578dcdd2.jpg)

...and lastly, laid on the rear deck to see what it looks like! Its all actually not that far out! I will just have to tackle the hours of little adjustments here and there, but I guess this is done AFTER bonding the rear deck on?

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2031/20130722_193038_zps34ee3742.jpg)

At this time, I am not bonding on anymore (i.e. the front clip and the rear deck) until after Donington so I can have a really good look at the completed cars to make sure I have everything correct..
Title: Re: Phils 4thirty build
Post by: Paul79 on July 23, 2013, 01:18:05 PM
Matey, you'll got that rear deck fitting really well (see circle). on some i see they have a gap there...good work
Title: Re: Phils 4thirty build
Post by: Phils99 on July 23, 2013, 01:36:36 PM
lol!! I have about a 10mm gap at the other side! the deck is only laid on at the moment.....
Title: Re: Phils 4thirty build
Post by: beemaman on July 23, 2013, 01:53:26 PM
as long as you have good gaps each side to allow for polyester and paint as this can be quite thick when done.but not too big a gap you could lose a small child in :) lol
Title: Re: Phils 4thirty build
Post by: Phils99 on July 23, 2013, 02:14:04 PM
Oh no! where has my grandson disappered to !! :-)
Title: Re: Phils 4thirty build
Post by: Nik the Greek on July 23, 2013, 06:19:30 PM
Oh no! where has my grandson disappered to !! :-)
Do you want me to come and help? ;D ;D ;D
Title: Re: Phils 4thirty build
Post by: s1monlebon on July 25, 2013, 09:04:34 PM
hi mate-i recently purchased a red dna f430 complete. its practically changed my life-for the better. been reading all your thread-hope all is well. im not a builder but a buyer when complete ha. i end up paying somebody to do even the smallest jobs. you are extremely brave doing what you've done-credit to you. how have you gone on with your toyota key....how have u disguised it phil, regards ricky
Title: Re: Phils 4thirty build
Post by: Phils99 on July 25, 2013, 09:11:34 PM
Hi Ricky,

Thanks for the kind words!

the key is the last thing for me to do! I have plenty to be getting on with at the moment!!

I will probably try and attempt what Lord Beany did in his thread as his key is brilliant!
Title: Re: Phils 4thirty build
Post by: Lord Beany on July 25, 2013, 09:56:22 PM
Why thank you kind sir! ;D

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on July 25, 2013, 10:57:22 PM
no worries beany!
Title: Re: Phils 4thirty build
Post by: Phils99 on July 28, 2013, 10:51:00 AM
Had a day in the sun on her yesterday and managed the following:

Thought I would create the holes in the rollbar surrounds for the rollbars

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2032/20130726_181631_zpsefea9c45.jpg)

I initially drilled them with a hole saw leaving a bit for me to sand down until im happy..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2032/20130726_182902_zpsc20c8cac.jpg)

I then sanded the edges until they were right...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2032/20130726_184043_zpsa88f89a7.jpg)

I then retrimmed the roof so that I can trial fit the rear deck and check that it doesnt touch the edges of the roof mechanism when opening closing with the roof up...I may have over trimmed it! but it doesnt matter as it will be going in the bin....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2032/20130726_192121_zpse0379878.jpg)

I also needed to cut this strap to allow the frame to go down....this strap pulls the last roof bar tight when the roof is up, I checked on manta's thread where he fitted the roof himself, and it looks like the DNA roof has its own strap which pulls the bars tight by clipping into the "T" piece that fits into the rear deck, so this should be OK to cut, I also unbolted a wire that was in the way, thats the wire you can see under the strap I am holding...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2032/20130727_103201_zps6ddff995.jpg)

I then looked closely at some pics I took of a DNA build and realised that the reason the pod retaining catches wont hold the pods is because they need a spacer to make them level, so I inserted a bolt in between the catch and the frame...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2032/20130726_193602_zpsc7469c0c.jpg)

These now work as they should!!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2032/20130726_193655_zpsec6d9afd.jpg)

To get the rear deck to close, you need to push the rear roof bar forwards to create room...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2032/20130727_103349_zpsf967a390.jpg)

So now...pods folded in and the deck does lower correctly so that bits OK...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2032/20130727_103441_zpsee840863.jpg)

I then laid the rear deck on the frame and lined it up and it looks like it will clear the roof edges...a little hard to check as it will be best with the deck bonded on, but then it would be too late!
I may bond the deck on with a few little blobs of sikaflex to test fit it...these can always be easily cut off if wrong!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2032/20130727_103858_zpsfd2c39fd.jpg)

So, looking at the rear deck, it seems to be lower than the rollbar cover. but, if I raise the rear deck, it then creates gaps at the front edge of the deck where it lines up with the body (the bit circled earlier by Paul!!)...so, I think I want to lower the rollbar cover. Having checked it out, it only really touches the metal rollbar holder part at the rear edge of the fibreglass, so I decided to remove this piece, I can then alter the height of the rollbar cover by trimming this edge down....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2032/20130727_134128_zps4692e921.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2032/20130727_134632_zps64eff32c.jpg)

I then decided to move onto something else, so I thought I would cut out the slot behind the license plate so that I can access the emergency deck pulls and the trickle charge socket..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2032/20130727_161203_zps78c8edac.jpg)

I then had a go at the petrol flap, firstly, I trimmed the flap itself as it had too much overhang on it, it probably needs more trimming, but Ill do that just before bonding it on.

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2032/20130727_170543_zps38a014de.jpg)

After bonding on the handles, this will be the second piece of bonding I have ever done!! here goes!!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2032/20130727_174329_zps2ee89186.jpg)

I then tied it up to hold it in place....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2032/20130727_182629_zpsf83cf4b1.jpg)

All in all a pretty good day....I am still weary about bonding the rear deck and front clip, so I will wait until after Donington so that I can get loads of photos/videos of completed ones in real detail (if the guys let me!!)

Meanwhile I am doing all the jobs that I can without these bonded on.
Title: Re: Phils 4thirty build
Post by: seriph on July 28, 2013, 01:53:59 PM
Bloody nice work mate. For someone wary about doing new things, doubleplus good work!!!

:)
Title: Re: Phils 4thirty build
Post by: rudycob1 on July 28, 2013, 05:26:50 PM
Phil,
Looking great mate. Nice work.
Just thought I'd mention that the rear shelf will need to come out for the roof to fold down properly.
Had to do it on mine.
Keep it going mate.
Rudy
Title: Re: Phils 4thirty build
Post by: Phils99 on July 28, 2013, 07:06:07 PM
thanks Seriph, much appreciated...

Rudy, ah, didnt realise that the shelf comes out, you can show me at donington...something else to get vids/photos of!
Title: Re: Phils 4thirty build
Post by: Paul79 on July 28, 2013, 07:39:33 PM
Great stuff Phil. Loving your work!  ;D
Title: Re: Phils 4thirty build
Post by: rudycob1 on July 28, 2013, 07:52:25 PM
No problem Phil.
Title: Re: Phils 4thirty build
Post by: Phils99 on August 10, 2013, 08:29:45 PM
Today I thought I would install the rear diffuser, so firstly I connected the four fins to the actual diffuser:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2033/20130810_115547_zpsc8a04d02.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2033/20130810_115554_zps17677efa.jpg)

I had to remove an extra part from the diffuser to stop it touching the exhaust, shown here in red pen:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2033/20130810_120037_zps8bf7e34e.jpg)

Once diffuser was installed, its obvious that I can see the silver exhaust through where the mesh will be, so I decided to paint this black with heat resistant paint:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2033/20130810_141151_zpsd8eed7f5.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2033/20130810_150847_zps8193bcef.jpg)

You can hardly see it now, and when the mesh is on you wont see it at all.

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2033/20130810_201050_zps0a75a1a8.jpg)

I then decided to have a play with the can of PlastiDip I bought, so I decided to paint my alloys on my other MR2 with Plastidip!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2033/20130810_163932_zps4e8aedba.jpg)

This stuff looks ace and if you change your mind, you just peel it off!!

I have always wanted a lambo orange car and you can get that colour in PlastiDip...I might dip my full MR2 !!!
Title: Re: Phils 4thirty build
Post by: beemaman on August 10, 2013, 08:49:04 PM
Hi phil
Looking good buddy .) nice to see things coming together :)

No probs phil if you want mr2 plasti dipping I do it and starts from £500 for small car.

Wicked stuff :)
Title: Re: Phils 4thirty build
Post by: rudycob1 on August 10, 2013, 10:51:13 PM
Nice one  :)
Title: Re: Phils 4thirty build
Post by: Lord Beany on August 10, 2013, 11:13:33 PM
I've just watched a load of YouTube videos on plastdip, never come across it before, it looks awesome.

Keep up the good work Phil.

I hope that first photo of the diffuser is a bizarre optical illusion regarding size, as it looks like the diffuser won't fit in your garage, let alone a completed car, lol.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on August 11, 2013, 12:55:46 AM
No beany its to scale, I asked DNA to scale the kit up by 30% as I am building a MONSTER SIZED FERRARI  ;D ;D ;D ;D ;D ;D


...only joking, its an optical iilusion!
Title: Re: Phils 4thirty build
Post by: Paul79 on August 12, 2013, 08:32:25 AM
Great work Phil. I've got my rear diffuser on, but not happy with it. It's not sitting right and it could need cutting like yours. Will try again once I have bonded the back on. Cheers for tip.
Paul
Title: Re: Phils 4thirty build
Post by: ghall164 on August 12, 2013, 02:43:14 PM
 :D great work mate diffuser looks great
Title: Re: Phils 4thirty build
Post by: Paul79 on August 31, 2013, 08:35:50 PM
Well Phil, now that Donnington is out of the way, we are all expecting a BIG update from you this weekend!  ;D ;D ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on August 31, 2013, 08:49:47 PM
im buzzing and ready to go...I know the way forward now....but, im visiting family all this weekend and im off to bruges next weekend....so you will get even further ahead of me mate, as it will be 3 weeks before i get another chance on her....
Title: Re: Phils 4thirty build
Post by: Phils99 on September 11, 2013, 09:10:39 AM
just an info update....

I intend to spend this weekend to do the following:

1. remove the bonded petrol flap as the mondeo flap is too deep in the housing so it needs unbonding and raising up..Im joining the "Beany" club here!!
2. Final line up and bond on the front clip
3. If any time left, line up the rear deck/roll bar surround/pods and get that bonded on

Also, due to personal problems (i.e a pending divorce!) I will be moving back into the Yorkshire clan around 19th October, so that means I have to dismantle my garage AGAIN and bring it back to Hull, the good news is that I am returning to my original house in Hull that has a much bigger garage!!
So during October, again I am not going to get much done :-(

Ill keep you posted
Title: Re: Phils 4thirty build
Post by: Paul79 on September 11, 2013, 09:50:42 AM
looking forward to seeing your updates matey...really sorry to hear about the personal problems....  :( take care.
Paul
Title: Re: Phils 4thirty build
Post by: Phils99 on September 11, 2013, 09:59:10 AM
cheers buddy...I have got to get back ahead of your build!!

oh, just found this, if mine isnt ready for Stonleigh next year, im gunna come in this!!

http://www.autotrader.co.uk/classified/advert/201147429956920/sort/default/usedcars/dealer/526457/page/1/postcode/hu152ut/advert-type/dealer-stock?logcode=dsp (http://www.autotrader.co.uk/classified/advert/201147429956920/sort/default/usedcars/dealer/526457/page/1/postcode/hu152ut/advert-type/dealer-stock?logcode=dsp)
Title: Re: Phils 4thirty build
Post by: Lord Beany on September 11, 2013, 04:08:44 PM
Bargain!
Title: Re: Phils 4thirty build
Post by: queasy rider on September 11, 2013, 04:40:52 PM
Sorry to hear about the divorce mate, good luck with your move back to Hull, sure you will soon settle back in!  :)
Title: Re: Phils 4thirty build
Post by: Phils99 on September 15, 2013, 09:37:11 AM
Yes! actually got some time to work on mycar today and the weather was lovely!!

So...its front clip time, I spent a while just getting the clip to line up with door and, having seen many DNA builds etc, having a large gap seems OK, so mine is about the same as those...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2034/20130914_100903_zpse7a5ab03.jpg)

I also checked the most important part which was to make sure the door doesnt catch when opening...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2034/20130914_100917_zpsf0da0278.jpg)

Same on the other side...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2034/20130914_102254_zpsb07b16d4.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2034/20130914_102306_zpsf0a96ca2.jpg)

I then bolted through the wing to the sill on both sides like this..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2034/20130914_102322_zps5828186d.jpg)

I then bonded the front clip on and it all seemed to go OK...no photos as it just looks the same as when it wasnt bonded on!

so.....I then decided to look at bonding the rear deck on, firstly I spent a lot of time lining up the frame until I was happy with it, it did need lowering at the rear so that the deck sat on it correctly, I then laid the deck on and test fitted it dry..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2034/20130914_143840_zpse938691f.jpg)

I have got my deck as low as I can, as I want these parts to run with the line of the car, I have noticed that on DNA builds, these parts have a finger sized gap underneath..I wanted mine low...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2034/20130914_143851_zps19849375.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2034/20130914_143903_zps80414d94.jpg)

I then put a few daps of sikaflex on the frame just to get the deck in place, if I am happy, I will inject more sikaflex into the gaps after..

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2034/20130914_145732_zpsbcea7108.jpg)

..and then placed the rear deck on....it didnt need much pressure to push it down as it was pretty close anyway...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2034/20130914_150331_zpsd36272e7.jpg)

Oh..during the day, I also cut off my petrol flap  :(  this will require more work to sort it out, but I will do this another day...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2034/20130914_143921_zps79e3bd27.jpg)

Thats it for now....hopefully may get some more time on it tomorrow....
Title: Re: Phils 4thirty build
Post by: Paul79 on September 15, 2013, 10:18:16 AM
Great stuff Phil. Sorry to hear about petrol flap - it is an arse of a job. On the frame where you put the stikaflex, are these the highest points of the frame? I.e is it just at these points where the lid touches the metal frame? And therefore elsewhere is there gaps for you to inject the stikaflex?
Title: Re: Phils 4thirty build
Post by: Phils99 on September 15, 2013, 12:19:33 PM
yea correct....tip for you...make sure you put it where the pin is for the lock down catches....this morning, I opened the deck and then it wouldnt close fully again on one side (the "second" click on the catch)...took me a while, but what it was was, as I tried to put pressure on the deck, it was just bending down and not pushing the frame down...that will be fixed when I get the sikaflex in there! for now I just padded it out with tough cardboard and it works OK now!!
Title: Re: Phils 4thirty build
Post by: ghall164 on September 17, 2013, 08:23:54 AM
 :) looking great phil you will have your pick of girls when this baby's built its coming along nicely well done enjoy Hull it's a great place to live
Title: Re: Phils 4thirty build
Post by: Phils99 on September 17, 2013, 12:00:26 PM
cheers ghall, im hoping the women come flocking!!
and as for Hull, I was born and bred there so I know it well!!
Title: Re: Phils 4thirty build
Post by: beemaman on September 17, 2013, 01:30:34 PM
I'm sure they will phill :) top down and sunglasses on :)

You need a great shiny paint job to lure them in (wink wink) lol

:) :)

All the best though phil I'm sure all will settle back down and you have a new beauty to admire now (in red)
Title: Re: Phils 4thirty build
Post by: Phils99 on September 17, 2013, 02:10:24 PM
you bet!!

cant wait to get to the paint shop stage...its just a little hard at the moment getting the time in the garage, im back in hull next 2 weekends visiting family and friends, I will then be packing for the 2 weekends after that and hopefully moving back to my house with the bigger garage in Hull weekend after that! phew!! its all go!

I am still hopeing to get this on the road next spring.....
Title: Re: Phils 4thirty build
Post by: Paul79 on September 17, 2013, 03:13:14 PM
you still working in London tues-thurs mate?
Title: Re: Phils 4thirty build
Post by: Phils99 on September 17, 2013, 03:14:01 PM
yep! Canary Wharf...
Title: Re: Phils 4thirty build
Post by: rudycob1 on September 17, 2013, 06:13:57 PM
Coming along great. See you soon
Title: Re: Phils 4thirty build
Post by: beemaman on September 17, 2013, 07:34:56 PM
Hopefully you can get it done for summer next year buddy would be nice :)

You will have plenty of time on her when your back in hull ??
Title: Re: Phils 4thirty build
Post by: Phils99 on September 18, 2013, 08:23:05 AM
rudy..cheers mate
beems..I am hopeing I will have more time after I have settled in....
Title: Re: Phils 4thirty build
Post by: TheWhitCar on September 18, 2013, 01:27:42 PM
Looking good Phil  8)
Title: Re: Phils 4thirty build
Post by: crossy on September 19, 2013, 07:39:16 AM
Coming along nicely Phil and great write ups on your build diary mate. Going to be a great car.  :)
Title: Re: Phils 4thirty build
Post by: Phils99 on September 19, 2013, 08:22:07 AM
cheers for the comments guys....
Title: Re: Phils 4thirty build
Post by: Phils99 on October 11, 2013, 08:34:04 PM
small update so you dont think ive given up.....

As some of you know, due to personal reasons, I will be moving back to my home town of Hull and rejoining the Yorkshire posse very soon!!

This move will happen next saturday the 19th October, so I needed to get my kit car moved ASAP.....talking to Madman, he offered to let me park it in his garage as, when I move back, its only a 30 min trip to his to collect and it gets rid of one of the 3 cars I will have to move!
So I accepted his offer and he offered to lend me his A frame to tow it down from Durham with...superb, what a guy!

So, with safety in mind, the night before I removed the ferrari wheels and removed the fake calipers as I didnt want them to come loose and get mangled as nothing is thread locked yet, I then tightened up the spacers and put the wheels back on with all 5 bolts (I was only using 3 before as I only moved it in and out of the garage at home), so far so good.

Saturday morning nice and early, I attached the A frame to the car, ran the light board and set off down the road, then as Madman had told me, after about a mile, I pulled over and checked it all for tightnes...all good!

I set off on the 70 mile journey down the A1 to pontefract, looking in the mirror every 2 mins to make sure it was still attached!

It towed like a dream (I was pulling it with my X5 in case people thought I was using my other MR2!!), I managed to get to the junction to come off at Potefract, 10 mins from Madmans place and I hit a red light...I waited for the green and then set off, looking in my rear view mirror as I did...WTF!! my offside rear wheel was at 45 degrees to the car and a load of smoke was coming from it!!!!!!!!!
I pulled into a bus stop and took a look....the bloody wheel with the spacer attached had come off the MR2 hub!!! Jeez!!
time to call International Rescue, or Madman :-)

"Hi Phil how you doing? where are you?"
"Hi mate...errrrmmmmm my wheel has fell off!!!"
"Hang in there, Im on my way"

10 mins later, Madman arrives with 2 spare wheels, a low trolley jack and a tool kit.....we manage to get an MR2 space saver spare on and slowly towed it back to his.....where mrs Madman greeted us with "is this one of those things where you say "I had one of those but the wheel fell off?"

ha ha very funny!!

When we got there, we had a closer look...and then I realised what an idiot I am!!

yes I removed the dummy calipers, yes I checked the bolts holding the front spaces on, yes I checked the allen keys holding the rear spacers on......NO, I forgot to remove the rear outer spacer and check the rear inner spacer, as, again, I had only used 2 bolts to secure these in place to move the car in and out of the garage and forgotten!! The two bolts I had used had slowly worked loose and then actually come off just as I had left the motorway!! How lucky can you get! It would have probably resulted in a total wreck if I had been doing 60 when the wheel came off...phew!!!

So the car is sat nicely in Madmans garage waiting for me to go repair the rear wheel that fell off and also check the other side.. and to then tow it back to Hull!

Madman, I own you loads mate, you have been a great help to me and a good friend.

By end of October, I hope to have the car back at mine and my original (bigger) garage operational again to get this thing finished and to paint ASAP.

Ill keep you posted on anything new....I am also kicking myself for not taking any pics when the wheel had fell off as they would have been interesting pics!!

until the next event.....
Title: Re: Phils 4thirty build
Post by: Paul79 on October 11, 2013, 10:08:38 PM
Mate. It's official. You are not allowed any more bad luck. It's the law. Will say a prayer for you. Sorry the hear what happened. Hope it is not too bad. I'm sure with your car in Alladin's cave something magical will happen.  ;D
Title: Re: Phils 4thirty build
Post by: Lord Beany on October 11, 2013, 10:48:50 PM
Something magical will happen?

Yeah, Madman will have painted it red. :P

I'm convinced mine escaped by the skin of it's yellow teeth. lol.

Madman, you truly are a gent and have helped or saved many of us at one point or another. It's a pleasure to know you mate.

Surely there can't be anything else to go wrong Phil. I hope the rest of your build goes smoothly.

Beany ;D
Title: Re: Phils 4thirty build
Post by: ghall164 on October 11, 2013, 10:53:09 PM
 :D wow that was lucky when you think what could have happened and mad man what a gent a real mate in a crysis hope things start to go right for you in hull all the best lads ;D
Title: Re: Phils 4thirty build
Post by: rudycob1 on October 11, 2013, 11:22:09 PM
Phil,
That was a close call mate but welcome back.
As for Madman, he's a one off. Simply great.
Like Beany said, he has helped many of us, me included.

I if need anything mate just call me.
See you soon.
Title: Re: Phils 4thirty build
Post by: seriph on October 11, 2013, 11:24:07 PM
Holy hell!

Reminds me of the time my wheel passed me on the highway many years ago. Very happy you had/have someone in your corner

Makes the world (and the wheels) go round

Title: Re: Phils 4thirty build
Post by: Indiana on October 12, 2013, 12:28:27 AM
small update so you dont think ive given up.....

As some of you know, due to personal reasons, I will be moving back to my home town of Hull and rejoining the Yorkshire posse very soon!!

This move will happen next saturday the 19th October, so I needed to get my kit car moved ASAP.....talking to Madman, he offered to let me park it in his garage as, when I move back, its only a 30 min trip to his to collect and it gets rid of one of the 3 cars I will have to move!
So I accepted his offer and he offered to lend me his A frame to tow it down from Durham with...superb, what a guy!

So, with safety in mind, the night before I removed the ferrari wheels and removed the fake calipers as I didnt want them to come loose and get mangled as nothing is thread locked yet, I then tightened up the spacers and put the wheels back on with all 5 bolts (I was only using 3 before as I only moved it in and out of the garage at home), so far so good.

Saturday morning nice and early, I attached the A frame to the car, ran the light board and set off down the road, then as Madman had told me, after about a mile, I pulled over and checked it all for tightnes...all good!

I set off on the 70 mile journey down the A1 to pontefract, looking in the mirror every 2 mins to make sure it was still attached!

It towed like a dream (I was pulling it with my X5 in case people thought I was using my other MR2!!), I managed to get to the junction to come off at Potefract, 10 mins from Madmans place and I hit a red light...I waited for the green and then set off, looking in my rear view mirror as I did...WTF!! my offside rear wheel was at 45 degrees to the car and a load of smoke was coming from it!!!!!!!!!
I pulled into a bus stop and took a look....the bloody wheel with the spacer attached had come off the MR2 hub!!! Jeez!!
time to call International Rescue, or Madman :-)

"Hi Phil how you doing? where are you?"
"Hi mate...errrrmmmmm my wheel has fell off!!!"
"Hang in there, Im on my way"

10 mins later, Madman arrives with 2 spare wheels, a low trolley jack and a tool kit.....we manage to get an MR2 space saver spare on and slowly towed it back to his.....where mrs Madman greeted us with "is this one of those things where you say "I had one of those but the wheel fell off?"

ha ha very funny!!

When we got there, we had a closer look...and then I realised what an idiot I am!!

yes I removed the dummy calipers, yes I checked the bolts holding the front spaces on, yes I checked the allen keys holding the rear spacers on......NO, I forgot to remove the rear outer spacer and check the rear inner spacer, as, again, I had only used 2 bolts to secure these in place to move the car in and out of the garage and forgotten!! The two bolts I had used had slowly worked loose and then actually come off just as I had left the motorway!! How lucky can you get! It would have probably resulted in a total wreck if I had been doing 60 when the wheel came off...phew!!!

So the car is sat nicely in Madmans garage waiting for me to go repair the rear wheel that fell off and also check the other side.. and to then tow it back to Hull!

Madman, I own you loads mate, you have been a great help to me and a good friend.

By end of October, I hope to have the car back at mine and my original (bigger) garage operational again to get this thing finished and to paint ASAP.

Ill keep you posted on anything new....I am also kicking myself for not taking any pics when the wheel had fell off as they would have been interesting pics!!

until the next event.....

I am glad you are ok and thanks to madman you could sort it out ;)

I live in Hull and so far I have still not seen any DNA in the flesh, so I'd love to pay you a visit when you are settled!!!
Title: Re: Phils 4thirty build
Post by: rudycob1 on October 12, 2013, 08:32:29 AM
Indiana, I live in Campsall , Doncaster , so not that far away.
If you want to have a look at my DNA, you're welcome.
Title: Re: Phils 4thirty build
Post by: Indiana on October 12, 2013, 10:01:32 AM
Indiana, I live in Campsall , Doncaster , so not that far away.
If you want to have a look at my DNA, you're welcome.


Thanks Rudy, sounds great!

Edit: sorry Phil I know is your thread, from now on I will use PM :)
Title: Re: Phils 4thirty build
Post by: MADMAN on October 13, 2013, 09:56:35 PM
Hey dont make my head any bigger. I have done no more than any other Yorkshireman would do.
Besides a life in the haulage, I,ve had help here and their, remember what goes round comes around.
If I could post pics Phill would be suprised to see his car allready painted, yep Red.
Beany you are for now the one that got away, untill next time ;D
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on October 13, 2013, 10:12:49 PM
Wow!! cant believe it Madman! youve finished my car for me and painted it in 2 weeks!!! amazing! Im so far ahead of Paul79 now :-)

Indiana, mate when I get it back you are welcome anytime, though I say Hull, I actually live in Gilberdyke, butno-one would know of that place except Hullies!!!
Ill let you know when she is "home" hopefully in about 3 weeks time....keep your eye on my build thread I will get pics etc this time!
Title: Re: Phils 4thirty build
Post by: Phils99 on October 13, 2013, 10:53:09 PM
oh just remembered, paul79 and lord beany, as for nothing else going wrong, my boss at work has just confirmed that my contract will NOT be renewed at the end if october due to a company "all contracters out" policy....so I will also be out of a job
Title: Re: Phils 4thirty build
Post by: rudycob1 on October 13, 2013, 11:24:35 PM
I'm sorry to hear this Phil.
All I can say to you is one door closes and another one opens and you sure deserve a big good door to open up for you.
If you need anything you know were we are mate.
Take care and see you soon.
Title: Re: Phils 4thirty build
Post by: Lord Beany on October 14, 2013, 01:03:20 AM
Beany you are for now the one that got away, untill next time ;D
MADMAN 8)

Don't tell Mrs Madman. Lol.

Phil,

Mate, what can I say? You're certainly having a bad run of luck. Let's hope things start looking up for you soon.

Keep smiling. ;D

Beany ;D
Title: Re: Phils 4thirty build
Post by: Paul79 on October 14, 2013, 08:33:33 AM
I'm sorry to hear this Phil.
All I can say to you is one door closes and another one opens and you sure deserve a big good door to open up for you.
If you need anything you know were we are mate.
Take care and see you soon.


I second that! Jeez! Chin up mate, it will be ok in the end.....karma and all that!
Title: Re: Phils 4thirty build
Post by: ghall164 on October 15, 2013, 09:15:08 AM
  :( sure hope it stops peeing on your parade soon phill know what that feels like been on short time a while now but things allways pick up and yours can only get better mate at least the builds something good in your life and with mates like madman what more can a man want  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on October 15, 2013, 09:27:29 AM
Cheers for the comments guys, it great knowing that we have forums like this where we have many virtual (and real!) friends!!

I love it!

Yea...just wanna get back on building my car to take my mind off all the crap.........
Title: Re: Phils 4thirty build
Post by: Phils99 on October 18, 2013, 11:50:46 AM
SOMETHING WENT RIGHT TODAY!!

Just towed down my green MR2 back to Hull last night using Madmans A-Frame without a problem!!

..just thought I would let you all know :-)
Title: Re: Phils 4thirty build
Post by: Paul79 on October 18, 2013, 12:01:26 PM
good to hear matey... things are looking up! good luck with the move
 
Title: Re: Phils 4thirty build
Post by: MADMAN on October 18, 2013, 03:16:05 PM
SOMETHING WENT RIGHT TODAY!!

Just towed down my green MR2 back to Hull last night using Madmans A-Frame without a problem!!

..just thought I would let you all know :-)

            Nice, at least you did,nt loose a wheel of that one ;) ;) say no more
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: rudycob1 on October 18, 2013, 05:26:45 PM
Great to hear that mate.
Title: Re: Phils 4thirty build
Post by: ghall164 on October 18, 2013, 06:44:06 PM
 ;D wahay can't keep a good man Down
Title: Re: Phils 4thirty build
Post by: Phils99 on October 24, 2013, 08:29:06 AM
something else good...went for an interview at Transport For London (who run the underground)...and got the job! (well contract!!)

...just deciding if I want to have a week off or not to sort my house/garage out....
Title: Re: Phils 4thirty build
Post by: Lord Beany on October 24, 2013, 10:14:23 AM
Excellent news Phil, chuffed to bits for you.

May the good fortune continue.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Paul79 on October 24, 2013, 11:02:55 AM
get it sorted matey and then you can get building again!!!!! hooray!!!  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on October 24, 2013, 11:27:30 AM
cheers guys!!

problem with the TFL job is they need me on-site 5 days a week (I was just doing 3 days a week and 2 from home with my existing role) so I will only get weekends to work on my baby....but, now im single, I can do what I like on the weekends!

Yes Paul...I need to catch up to you! your flying past me now....
Title: Re: Phils 4thirty build
Post by: Phils99 on November 06, 2013, 05:11:16 PM
MY GARAGE IS SETUP AND READY!!!

Hurray! Im ready to rock and roll......first customer, the green machine...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2035%20move%20back%20to%20Hull/20131105_153201_zps246e0d7d.jpg)

The front disks and pads were feeling awful when breaking, with all thats been going on with the move etc, I hadnt had time to look at them, so I ordered new disks and pads about a week ago and made this my first job as my green machine is a daily runner...cannot believe the state of the disks I took off! I have never seen front disks get like this on a daily runner, I had the rear ones on my Audi A4 look like this....jeez!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2035%20move%20back%20to%20Hull/20131106_164219_zps7f1d49a6.jpg)

Anyway, today I headed out to Madmans to go fix my car up to tow home, I removed the MR2 spare we had used to get it to Madmans and then removed the calipers and disk to check out the damage...not too bad really, the disk will need replacing and it looks like the rear threads are the same as the front ones, i.e. bolts that push in from the rear with splines on, well, due to the wheel wobbling loose, it looks like all the splines have been rubbed off from the hub (sorry forgot to take pictures), so, all in all, it looks like I will need to replace the offside rear hub and the rear disk....pretty lucky (as madman keeps telling me! :-) )

Due to the wear on the hub, I can only get 2 bolts in, so this will have to do to get her home (30 miles), I fitted the original MR2 rear wheel and mega tightened the 2 nuts.

Next I thought I would check the nearside rear wheel to see what damage was caused there (even though the wheel didnt fall off!)...RESULT! I had actually put all 4 nuts securing the inner spacer on this side....then I realised what I will have done, I must have fitted the nearside spacers first and used 4 short wheel nuts, then when I came to do the offside, I only had 2 short wheel nuts left, due to the fact that 2 of them on the original car are locking wheel nuts, so I thought "no worries, its not gunna be driven like that only when its put on a flat bed for paint shop, and then I will have put the MR2 wheels back on"...and then forgot what I had done when I towed it with the A-frame!

So I then set off very slowly on the 30 mile drive home, constantly checking the wing mirrors for signs of problems.....and yes, I managed to get her home safely...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2035%20move%20back%20to%20Hull/20131106_135747_zps666d11cc.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2035%20move%20back%20to%20Hull/20131106_135805_zps3379835a.jpg)

I unhooked the tow frame and then got her into the garage for the night....

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2035%20move%20back%20to%20Hull/20131106_164208_zps18620b18.jpg)

I will start to empty out all the bits I had stuffed inside during the move tomorrow......

My build can now continue!!
Title: Re: Phils 4thirty build
Post by: beemaman on November 06, 2013, 06:09:54 PM
Good to have you back buddy and you will get loads done now the weight of a women's off your shoulders :)

Look forward to the commencing photos :)
Title: Re: Phils 4thirty build
Post by: Paul79 on November 06, 2013, 07:57:56 PM
Welcome back build partner! Good to see you. So what are the first jobs on the list?
Title: Re: Phils 4thirty build
Post by: Phils99 on November 06, 2013, 09:05:24 PM
I think I will do the following:

fix the hub when I get one!
cut the front clip brace bar off
line up the rollbar surround with the rear deck
bond on rear deck fully
fit pods

I really should do the petrol flap, but im putting it off for a bit!!
Title: Re: Phils 4thirty build
Post by: Paul79 on November 06, 2013, 10:09:29 PM
I know what you mean about the petrol flap. It isn't the most enoyable of jobs. I put it off for ages as well. loving the fact your garage has a toilet in there... don't want to waste presious build time seconds going back into the house for the loo!!  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on November 06, 2013, 10:10:51 PM
absolutely! its also great for family BBQs!
Title: Re: Phils 4thirty build
Post by: rudycob1 on November 06, 2013, 10:36:38 PM
Great to see you back and getting stuck in mate.
All the best.
Rudy
Title: Re: Phils 4thirty build
Post by: Phils99 on November 08, 2013, 07:54:00 PM
Cheers Rudy...

I spent a little time last night (Thursday) and used Pauls tip to use the electrical connector block insides for the cable clamps

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131107_132901_zps70598e54.jpg)

I also trimmed the roll bar support frame bracket down a bit so it doesnt foul the seatbelt, I also added a few washers underneath the bracket to make it bolt down flat.

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131107_154550_zps4e6c39e8.jpg)

I then messed around trying to line up the rollbar surrond with the rear deck...with no success..so I abandoned that job as it was getting late.....

I will carry on tomorrow (Friday)
Title: Re: Phils 4thirty build
Post by: Phils99 on November 08, 2013, 08:07:43 PM
So, I decided to mess around with the bonnet today for a change...

Firstly, I needed to remove the brace bar, I had left this one whilst I was ready for the bonnet to be fitted

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_132958_zps625f98d0.jpg)

I made a pencil mark along where to cut

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_134117_zps8e3e6e2a.jpg)

I then cut one end

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_133401_zpsb0c83f62.jpg)

and then the other to free the brace bar

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_134347_zps50595cdc.jpg)

...and then laid the bonnet on just to see!
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_135000_zps3ce4adb5.jpg)

So, having communicated with Paul, he recommended that I fit the scuttle BEFORE the bonnet to assist in lining it up, so I did!!
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_135913_zps37dce2d0.jpg)

Here you can now see the gap that will need to be added to to make the scuttle fit correctly

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_135922_zpsd36d5098.jpg)

I then laid the bonnet on and marked where the scuttle will need to be cut
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_140015_zps2eb060a5.jpg)

I then cut the front grill part of the scuttle off, as I will reuse this piece after trimming

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_141811_zpsa880b2c4.jpg)

I replaced the scuttle after trimming and laid the bonnet on again to make sure its clear

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_150029_zpsf0a39203.jpg)

So, whats left is for me to refit the scuttle "grill" back into the trimmed down opening...I will leave this as a job to do whilst its at the paint shop..
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_145414_zps5726e803.jpg)
Title: Re: Phils 4thirty build
Post by: Phils99 on November 08, 2013, 08:21:24 PM
now its bonnet fitting time!!

Firstly, I found the nuts and bolts I had ordered for this job, they are M8 x 50mm nuts and bolts

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_151520_zpsd75c2531.jpg)

I then drilled out the holes in the wings for the hinges

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_152704_zpsc013a577.jpg)

Whilst I was at it and whilst I remember, I bolted down the front of the car onto the plate underneath

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_153456_zps54aafd41.jpg)

I then fit the hinges to the bonnet

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_153743_zpsc79485eb.jpg)

and again, stealing Pauls idea, used a pole to hold it in place whilst I inserted the long bolts into the wings

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_153920_zps2a3f9f8e.jpg)

I was then able to easily get the 4 bolts in

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_154339_zpsf1436441.jpg)

I then found that I needed to increase the length of the slots on the bonnet side of the hinges, I guess this is because I bolted the hinged to the wings a little to close to the front of the car

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_162011_zps48dc1ea0.jpg)

Its now a case of adjust, check, adjust, check and so on, now I am doing mine with NO bonnet stops or bonnet catch (thanks Paul) to just line up the bonnet, the stops should only really stop the bonnet from rattling and not help line it up, so I will do these last

After about 1.5 hours, of adjusting, I decided to call it a day and will pick it up tomorrow (Saturday), here is the bonnet nearly lined up!!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2036/20131108_165038_zps8dcf7aac.jpg)

Thats all for now
Title: Re: Phils 4thirty build
Post by: Paul79 on November 08, 2013, 08:46:36 PM
Welcome back Phil. That bonnet looks lined up just lovely. There you go.. you managed to get it done in an afternoon!  Took me a lot longer!  ;D
Title: Re: Phils 4thirty build
Post by: beemaman on November 08, 2013, 09:02:36 PM
Good work phil its getting there buddy.just imagine it in glossy red mmmmmmmmnnnnn nice :)
Title: Re: Phils 4thirty build
Post by: Phils99 on November 10, 2013, 02:48:48 PM
cheers guys...
Paul, as you told me, the camera pics can be deceiving! the bonnet needs a bit more work yet!!
Title: Re: Phils 4thirty build
Post by: MADMAN on November 13, 2013, 12:42:07 PM
Looking good Phil,
                          I,ve got a spare Italian flag, if you have a blank wall on your new garage (free) let me know
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on November 13, 2013, 01:26:14 PM
cheers madman...yea ill take it iff your hands!
ill pick it up when I return your A frame probably weekend after next if that's ok?
Title: Re: Phils 4thirty build
Post by: MADMAN on November 14, 2013, 07:00:38 PM
cheers madman...yea ill take it iff your hands!
ill pick it up when I return your A frame probably weekend after next if that's ok?
Yeah thats fine, see you then
Title: Re: Phils 4thirty build
Post by: Phils99 on December 15, 2013, 09:21:51 PM
Havent posted for a while due to not having a minute spare in my life at the moment to work on my car :-(

I did manage to get some time on it last Sunday, but forgot to post my progress, its not much as it was all about bonnet allignment which is a matter of "put it on", "take it off" and tweak the position etc etc etc...

befor I start a BIG BIG thank you to Crossy, who actually remembered that I needed a rear hub and took one off a car for me and sent me it - AND DIDNT WANT A PENNY FOR DOING IT!! what a star...thank you so much mate, the drinks are on me at the next show we are at!

Here is what he sent me:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2038/20131208_160105_zps11bd27e5.jpg)

Just need time to install it now!!

Anyway, the bonnet is secured by the 2 hinges in the kit as so...for more details, see Pauls build!

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2038/20131208_155458_zpsc2246221.jpg)

These hinges can be altered where they are bolted to the bonnet and where they bolt to the front clip, its these you mess with until you get it lined up.

I messed with these for hours until I got the bonnet as lined up as I could, I did this WITHOUT the bonnet catch fitted or any bonnet stops. My bonnet is a little low, but, when I fit the bonnet stops, these will be used to raise the bonnet at the front of the car and near the windscreen.

I then fitted the bonnet catch bracket, I lined up the "V" shape with the wiper, as, when I lowered the bonnet and took a look, I found that the bonnet catch moulded into the bonnet lined up with the middle wiper spines.

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2038/20131208_151057_zps6f59aa36.jpg)

This was bolted on with locking bolts so it shouldnt move

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2038/dece77cc-9580-47e1-a17a-504aea98eed3_zps91bfda67.jpg)

Next, I modified the original  MR2 front bonnet catch as by firstly removing these pieces:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2038/20131208_132035_zps4384b8ef.jpg)

And then removing the bonnet safety catch, this is not needed on the DNA 430, as the bonnet opens the opposite way to a normal bonnet, so if it uncatches whilst driving it wont flip up:

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2038/20131208_132829_zps4da98edc.jpg)

This was then mounted onto the mouting plate
(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2038/20131208_155439_zps6ada9f41.jpg)

I then adjusted the height of the bonnet catch so that it was a low as possible so when the bonnet stops are fitted, they will keep the bonnet tight into the catch (no pics of this) I then took a few pics of the bonnet alignment...

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2038/20131208_155703_zps318ab282.jpg)

(http://i1120.photobucket.com/albums/l488/phils999/DNA%20430%20Build/Day%2038/20131208_155650_zps230ae416.jpg)

I am hoping to get some time on it over the xmas holiday, but family comes first!!
Title: Re: Phils 4thirty build
Post by: rudycob1 on December 15, 2013, 09:38:20 PM
Glad to see you getting on with things.
Car looking good mate.
See you soon.
Title: Re: Phils 4thirty build
Post by: ghall164 on December 15, 2013, 09:49:21 PM
 ;D looking good Phil glad to see life's treating you well and loving the new garage plenty of room to crack on with the build real pleased for you mate
Title: Re: Phils 4thirty build
Post by: beemaman on December 15, 2013, 09:52:44 PM
great work phil soon be together and off for paint.will you be doing some over xmas time buddy :)
Title: Re: Phils 4thirty build
Post by: Paul79 on December 15, 2013, 10:02:21 PM
welcome back partner!  8)
Title: Re: Phils 4thirty build
Post by: MADMAN on December 16, 2013, 10:54:27 AM
Keep up the good work Phil, should go better with four wheels on ;) ;)
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: dman1409 on January 28, 2014, 12:50:44 AM
Hey Phill!!

I have been catching up with your thread ... Sorry hear about your run of bad luck!

I see your build is coming along nice! Great skill mate!

Hope to start my build in March.... Almost got all oem parts collected that i need!

Cheers!
Title: Re: Phils 4thirty build
Post by: Phils99 on January 28, 2014, 08:07:41 AM
cheers guys, thanks for the comments, they really help.....im hoping that I have no overtime on this weekend and can put some time in!
Title: Re: Phils 4thirty build
Post by: dman1409 on February 01, 2014, 12:37:41 AM
Have an extra steering wheel becuase i bought an oem one...

Are you interested?!

(http://i1113.photobucket.com/albums/k507/Dman1409/Steering%20wheel/A1ACE015-D4A8-407D-AB61-3CD7FE0882F9.jpg) (http://s1113.photobucket.com/user/Dman1409/media/Steering%20wheel/A1ACE015-D4A8-407D-AB61-3CD7FE0882F9.jpg.html)

(http://i1113.photobucket.com/albums/k507/Dman1409/Steering%20wheel/8379A50D-422F-4720-B295-724C9CAAB0F8.jpg) (http://s1113.photobucket.com/user/Dman1409/media/Steering%20wheel/8379A50D-422F-4720-B295-724C9CAAB0F8.jpg.html)
Title: Re: Phils 4thirty build
Post by: Phils99 on February 02, 2014, 09:17:24 PM
YEEHAW!!

Managed to get myself into the garage today and work on the car....my problem is that I have SOOOO much to do, I didnt know where to start!

I decided to start by fixing the things that are "broken" as follows:

Petrol flap issue - I needed to remove the flap from the Petrol flap housing, as this had been previously cut off the car after being bonded on, I decided to scrap it completely and I will contact DNA and buy another one, so today I rescued the Mondeo petrol flap from the housing and threw the housing away, when I get a new one, then it will be easier than trying to make what I have work.

Emergency rear deck release pull issue - when my wheel "fell off" (see earlier posts), it rubbed against the pull cable and wore away the outer sheath making the cable not work corectly, I had to disconnect it, pull the wire back through it and cut out the worn bit. This worked OK as it still reached the latch so I also tidyed up the cable run so it will always be out of the way of the wheel (see pic 1).

Drivers door handle issue - whilst fitting the drivers door handle, I levered it a little to line it up, this seemed to have slightly bent the locking latch on the hinge and caused the hinge to unclip after using it, I make some slight taps on the part that the hinge should latch on, and, after the third adjustment it latched complety as it should! (no pics on this as not much to really see)

Rear drivers hub issue - after the wheel fell off, it damaged the splines that hold the wheel studs in and therefore you are not able to get 2 of the studs to stay in the hub, I sourced a new hub (thanks Crossey!) and started the task of stripping the existing hub off the car, all went OK until I come to the wheel hub end nut...I then realised I havent got a socket this size, on MR2ROC, one of the posts said that it needs a 30mm socket so I made the 1 hour round trip to Halfrauds to get one, only to find that it doesnt fit! Anyone know the size of this? I think its 32mm?. So this job is held until I get the right wheel hub nut socket (see pic 2)

So, after those jobs, I thought I would get back on track and take a leaf out of Pauls "Build manual" and secure the rear end/diffuser with brckets.

I went into Tool Station in Hull and bought a load of brackets...cannot believe how cheap these are, around 59p each! (see pic 3)

I took one of the flat bars and bent it to hold the drivers side diffuser by using the existing diffuser securing bolt and an existing screw thread available in the cars frame (thanks Paul) it also needed a slight twist in the bend (see pic 4)

This was then secured to the car and the diffuser making it rock solid at that side! (see pic 5)

The passenger side had an old exhaust hanger in the way  (see pic 6), so I cut this off and created the bracket for this side exactly the same as the other side (see pic 7)

I then bent the supplied diffuser brackets that hang the diffuser to the rear end, left pic is how they come, right is bent (see pic 8) they now hold nicely, but I need to take the diffuser off to fit them and my day ran out!

I now need to order a load of stuff (new rear discs, petrol flap carrier, bolts for the diffuser brackets, hub socket) so I can carry on next time.


Title: Re: Phils 4thirty build
Post by: Paul79 on February 02, 2014, 09:29:34 PM
Good to have you back on it mate. Hopefully the 'Manual' will speed things up for you. Lol  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on February 02, 2014, 09:31:13 PM
certainly will buddy!
Title: Re: Phils 4thirty build
Post by: cheets on February 03, 2014, 12:27:48 AM
Hi bud will have a look tomorrow morning for the size of the  wheel hub  nut ….. nice to see you back on it :)
Title: Re: Phils 4thirty build
Post by: cheets on February 03, 2014, 10:43:19 AM
  ??? Sorry bud I have got me wheals on so can not get the socket on to try it but I do think it is a 32mm
Title: Re: Phils 4thirty build
Post by: Phils99 on February 03, 2014, 12:16:05 PM
no worries....thanks for trying mate
Title: Re: Phils 4thirty build
Post by: Mario on February 03, 2014, 07:41:22 PM
Hi Phil99 Builds coming on a treat mate looking good - If you need hub nut size bell me tomorrow & i'll get it of mine if this helps mate.
Cheers Mario
Title: Re: Phils 4thirty build
Post by: Mario on February 03, 2014, 07:42:14 PM
Sorry mate Tel 07773660531 Mario.
Title: Re: Phils 4thirty build
Post by: dman1409 on February 13, 2014, 09:10:00 PM
(http://i1113.photobucket.com/albums/k507/Dman1409/F83FDAE4-73B4-4EDA-80AC-77FCBFDF03FA.png) (http://s1113.photobucket.com/user/Dman1409/media/F83FDAE4-73B4-4EDA-80AC-77FCBFDF03FA.png.html)

Yoo phill!

I am buying a bunch of these DRL lights with switchback turn signal...

Let me know if you also want a set....

Cheers
Title: Re: Phils 4thirty build
Post by: Phils99 on February 13, 2014, 09:37:57 PM
interested at the right price.....
Title: Re: Phils 4thirty build
Post by: dman1409 on February 15, 2014, 11:33:02 PM
There are different quality's of this product... I receive my samples this week... I think around 60 euro's for a set... Ofcourse i only use top quality..



Title: Re: Phils 4thirty build
Post by: Phils99 on February 17, 2014, 11:32:15 AM
Not a build update as I had a weekend in London this weekend so hope to work on the car next saturday....anyway, whilst in London, I visited Harrods as you do to buy the cheapest thing to get a carrier bag...when I came out side, this was parked on a yellow line with a parking ticket on it!

I then took a walk round Knightsbridge and saw the following within 10 mins!

Another Lambo Aventador
1 x Lambo Murci
3 x Maclaren 12c's
1 x Ferrari 360
1 x Ferrari 430 Spider
1 x Audi R8
LOADS of Aston Martins

....I just wanted to stay there all weekend, but the other half wanted to see sights in London :-(



Title: Re: Phils 4thirty build
Post by: ghall164 on February 17, 2014, 06:37:46 PM
 ;D I'm with you pal what more do you need to see sounds like heaven :o
Title: Re: Phils 4thirty build
Post by: Phils99 on February 22, 2014, 11:43:58 PM
Had a good day on the car today, so I decided to firstly finish off the rear diffuser.

First off all if you remember last time I bent the supplied brackets so now I drilled and screwed them on as show in pic 1 and 2

Pic 3, 4, 5 and 6 show how I created the template for the rear diffuser mesh by drawing the shape on cardboard, extending it, then taping it to the mesh, I then used my angle grinder to cut the shape out.

Pic 7 shows the mesh laid over the hole, pic 8 then shows the mesh with the edges folded over, I will bond this to the diffuser when it comes back from body show

more to come....




Title: Re: Phils 4thirty build
Post by: Phils99 on February 22, 2014, 11:52:10 PM
so mesh from the other side now looks like pic 1

So now onto the mesh just above the diffuser, not everyone does this, but the real car has it so mine will! Pic 2 shows marking the mesh roll after I measured what is needed, pic 3 is the piece cut off.

Pic 4 shows where i nibbled a bit of mesh out so that it would fit in front of the brackets and they would hold it in. It was at this point that I realised, that I had bent the brackets wrong, so I straightened them and bent the part with the screw hole in wider to allow for the slope of the diffuser, this fit much better.

Pic 5 and 6 show what it looks like fitted

I the removed the diffuser, took the mesh out, refitted the diffuser and bonded the brackets onto the rear body as shown in pic 7

more to come....
Title: Re: Phils 4thirty build
Post by: Phils99 on February 23, 2014, 12:09:27 AM
Next, onto securing the rear sills

pic 1 shows passenger side where I took a metal barcket and used the existing bolt hole and then bonded to the sill

pic 2 show drivers side, but I needed to bend this bracket to make it lay flat

Next onto the scuttle, it was getting on my nerves trying to keep fitting it with the excess on and I thought I will probably damage the scuttle/wing paint work when its done, so I decided the trim the ends off! pic 3 and 4 show this, its MUCH easier to get on and off now!

Onto the frunk....having trimmed the bottem right corner previously, it now need to be trimmed to allow for the bonnet release catch as shown in pic 5

I then decided to trim the frunk surround, this took ages as I laid it on, then mark when I needed to trim but leaving a big safety margin! I then kept trial fitting it and taking a little more off here and there until it fit, in the end you remove quite a bit from this part and its pretty "floppy" so be careful not to let it snap. pic 6 and 7 show it fitted

Well, it seemed to take all day to get these bits done, but Im pretty happy as its completed about 5 or 6 jobs off my list.

I was also going to add more sikaflex to my rear deck as I only "dabbed" it on in case I need to remove it, but the Sikaflex had gone off, so I have ordered some more off the 'bay tonight for next time.

Hopefully get aniother day next week.
Title: Re: Phils 4thirty build
Post by: Paul79 on February 23, 2014, 10:20:51 PM
Great progress mate. Good to see you back on it. Great day for it as well.  8)
Title: Re: Phils 4thirty build
Post by: Phils99 on February 23, 2014, 10:26:29 PM
cheers pal...its good to get a good day and actually achieve some progress!

Cant believe yours is going to piant very soon!! well done mate.
Title: Re: Phils 4thirty build
Post by: cheets on February 23, 2014, 10:57:35 PM
Nice work Phil keep going like this and you will be dun before me :)
Title: Re: Phils 4thirty build
Post by: ghall164 on February 24, 2014, 06:31:11 PM
Progressing well Phil well done looking good
Title: Re: Phils 4thirty build
Post by: beemaman on February 24, 2014, 06:46:04 PM
coming a long now phil when youve had a few good weekends on her it will start forming like pauls did.

keep up the good work buddy :)
Title: Re: Phils 4thirty build
Post by: Lord Beany on February 24, 2014, 07:24:38 PM
Getting there mate. All these little jobs take so long.

Keep at it and you'll soon be in paint.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Paul79 on February 24, 2014, 08:27:07 PM
coming a long now phil when youve had a few good weekends on her it will start forming like pauls did.

keep up the good work buddy :)


yeah, you could do what i do and get up at 4am to start work on the car, to get more hours in! while the world sleeps, Paul builds!!! just don't switch the angle grinder on till after 9am!! unless you really want to p#ss your neighbours off! LOL  ;D
Title: Re: Phils 4thirty build
Post by: rudycob1 on February 24, 2014, 08:36:25 PM
All this work is very satisfying as some of us know. Everyday is one step closer. Enjoy it mate and great work.
Title: Re: Phils 4thirty build
Post by: Phils99 on February 24, 2014, 08:55:14 PM
thank you so much for all the comments guys....Im sat here in london wishing I was at home so I could do a bit on my build!

Your comments and well wishing really do inspire people, this has got to be the friendliest and most inspiring forum I have ever been a member of...and I love it!
Title: Re: Phils 4thirty build
Post by: Paul79 on February 24, 2014, 10:32:21 PM
thank you so much for all the comments guys....Im sat here in london wishing I was at home so I could do a bit on my build!

Your comments and well wishing really do inspire people, this has got to be the friendliest and most inspiring forum I have ever been a member of...and I love it!

Matey, there are tons of things you can do on your build away from the actual car. I should know, I've done enough. I know you can't lug the front bumper down to london on the train (LOL) but things like all the wiring, you can prepare the adaptors and extend the wires and get them all labelled up ready to connect to the car. All that will certainly fit in your suitcase! there are loads of bits that need rubbing down, like rear pods, exhaust surrounds, the steering wheel parts etc.. all those crap jobs that aren't much fun but need to be done. these bits aren't too big to transport. i'm sure you could even prime and paint those bits down in london. if you need to borrow some tools while your down here, let me know and we can sort something out.  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on February 24, 2014, 10:41:39 PM
im sure the landlord I rent the small single room off of would not be impressed with a load of mess from sanding down!!


I may bring the wires down as I have been mapping out the wiring due to mine being a pre facelift and different to yours!
Title: Re: Phils 4thirty build
Post by: Phils99 on March 02, 2014, 10:32:45 PM
Due to my daughters car breaking down this morning, I only got half a day on it today, but I think I did OK!

Pic1 and pic 2, I managed to finish replacing the hub after I took deliver of a hub puller.

Pic 3, I protected one of the reflectors so I could use this one to line up the holes required for fitting

Pic4, I then drilled the holes, if you look closely, you can see an imprint in the fibreglass for where they need to be

Pic 5, both reflectors fitted

Pic 6, I then checked the fitment of the rear lights as I had previously cut these out. These are not secured as yet as I will get some brackets to enable me to use the upper bolts to secure them with as the other guys have done.


...continued

Title: Re: Phils 4thirty build
Post by: Phils99 on March 02, 2014, 10:42:42 PM
...continued

Pic 1, I then had to do a little sanding to allow the high level light to fit nicely, again, this is not secured as yet until I get some thinner brackets during the week...Robert Dyas here I come!

Pic 2, I measured and cut out the mesh I would need for the part that sits behind the prancing horse

Pic 3, As I want it to be as close as possible to the real one, I made a plastic plate to emulate the metal bracket that the real one has behind the prancing horse. This will also be used to help mount the horse on the mesh

Pic 4, mesh fitted

Pic 5, plate behind mesh fitted, the mesh and plate are only gaffa taped on at this time as they will be bonded on after paint.

Pic 6, Final rear end picture, a little blurred.... (I have removed the brake light so it doesnt fall out!)
Title: Re: Phils 4thirty build
Post by: cheets on March 02, 2014, 11:40:09 PM
Looking good Phil :)
Title: Re: Phils 4thirty build
Post by: rudycob1 on March 03, 2014, 12:09:51 AM
Great work mate, keep it up.  :)
Title: Re: Phils 4thirty build
Post by: seriph on March 03, 2014, 08:51:16 AM
I think I smell OCTANE! Won't be long now

:D
Title: Re: Phils 4thirty build
Post by: Phils99 on March 03, 2014, 09:30:04 AM
cheers guys.....still loads to do yet, but Im happy with progress....
Title: Re: Phils 4thirty build
Post by: MADMAN on March 03, 2014, 09:33:16 AM
Due to my daughters car breaking down this morning, I only got half a day on it today, but I think I did OK!

Pic1 and pic 2, I managed to finish replacing the hub after I took deliver of a hub puller.

Pic 3, I protected one of the reflectors so I could use this one to line up the holes required for fitting

Pic4, I then drilled the holes, if you look closely, you can see an imprint in the fibreglass for where they need to be

Pic 5, both reflectors fitted

Pic 6, I then checked the fitment of the rear lights as I had previously cut these out. These are not secured as yet as I will get some brackets to enable me to use the upper bolts to secure them with as the other guys have done.


...continued


Make sure you fit all nuts this time ;) ;) sorry mate I could not resist ;D
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on March 03, 2014, 10:13:28 AM
Lesson Learnt big style I think!!
Title: Re: Phils 4thirty build
Post by: Paul79 on March 03, 2014, 12:10:13 PM
that last picture looks bloody awesome matey..  8)  well done.. catching me up now!!!  ;)
Title: Re: Phils 4thirty build
Post by: ghall164 on March 03, 2014, 05:44:05 PM
One thing that came out of the lose nut saga was you found out what a top bloke madman was  ;D top job Phil looking great
Title: Re: Phils 4thirty build
Post by: Phils99 on March 03, 2014, 06:29:43 PM
I also found out what a top bloke Crossy was as well...to be honest, everyone on here is a top bloke its such an amazing "club" and I cant wait for this years shows! even though my car wont be ready....
Title: Re: Phils 4thirty build
Post by: MADMAN on March 03, 2014, 10:28:44 PM
I also found out what a top bloke Crossy was as well...to be honest, everyone on here is a top bloke its such an amazing "club" and I cant wait for this years shows! even though my car wont be ready....
            Thats me and Crossy going red :-* But you are correct it is an amazing club with amazing members all willing to help and advise each other when they can. Long may this club Rule
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on March 06, 2014, 05:59:10 PM
just a "verbal" update today....

Took Pauls advice (via PM) and, as I am working in London 5 days a week, I decided to bring some stuff down with me to do.

I measured how much I would need to extend my rear lights wiring by and then, using as close to the MR2 colours as I could, I cut 14 lengths of wire (as 2 connections are not use in the superseal plugs or it would have been 16!) and brought the superseal plugs and a crimper/cutter down with me!

These superseal plugs are very fiddly and time consuming, so may as well do this whilst sat in my room!
The little blue seals that go on the wires are tough to initially get on, also, I found that crimping the pins on the wires sometimes didnt grab the wire as good as I would have liked, so I think I will put a dab of solder on these when I get home as I dont want these failing when assembled.

I wasnt fully sure how the litle blue seals fit together, but a little googling revealed this diagram, and, suprising to me, you actually crimp the little blue seals to the pin! glad I checked!

If you dont know, you dont know!!

Title: Re: Phils 4thirty build
Post by: Phils99 on March 09, 2014, 07:37:04 PM
Had a nice "summers" day in the garage today...what great weather!

Pic 1. Finally painted up and reassembled the rear hub and brakes at last!

Pic 2. I thought I would invest in a Rivnut gut and a bunch of rivnuts, as I decided, like cheats to make my rear diffuser so you should be able to remove it without having to take the wheel arch liners out to hold the nuts whilst you unscrew the allen bolts, so I make a few plates and inserted a rivnut into them

Pic 3. I then bolted the diffuser on using these plates on both sides (passenger side shown)

Pic 4. I then added some Sikaflex and tightened up the bolts to dry on both sides (drivers side shown)

Pic 5. I also make some extra brackets for the rear lights, I decided that just 1 will be enough as they are pretty well solid with these 2 bolts on both sides (passenger side shown)

Pic 6. and then bonded these on by applying Sikaflex then tightening them up (drivers side shown) ..sorry the photo came out blurred

Pic 7. I also make brackets for the rear light....

Pic 8. ...and bonded these in place

continued.....






Title: Re: Phils 4thirty build
Post by: Phils99 on March 09, 2014, 07:51:03 PM
one thing that did happen when I was removing the hub is that a bolt that holds the cable for the ABS sensor snapped whilst undoing it so it left the rusted thread in place

Pic 1. shows snapped bold, I drilled this out

Pic 2. then inserted a rivnut

Pic 3. good as new!! Rivnuts! what an amazing tool!

Pic 4. I noticed that the rear of my rear deck was "flexing" in the corners, so I inserted a piece of wood and Sikaflex'd around it to hold it in place, I also added more Sikaflex to the rear deck bonding as I had only dabbed it when I bonded it on.

Pic 5. Next, I stole another idea off Cheets (sorry mate, hope you dont mind!) as I wasnt happy with my deck release pulls the way they would be in the way of the air intake pipe from the upper air intakes and also the way the end of the cable didnt seem to fit into the adjuster due to the tight angle, so I fabricated a couple of brackets so that the cable can come through the hole in its outer cover so it makes the bend better, this is a great solution!
i am still hoping to use solenoids for the real deck releases

Pic 6. you can now see the cable angles up into the rear wing leaving the air intake clear

cant wait until next weekend to get more done, I really enjoyed today, even though it doesnt seem like I have done much, these little jobs can take a long time!
Title: Re: Phils 4thirty build
Post by: Furrari on March 09, 2014, 07:59:50 PM
Rivnuts are not intended for replacing damaged threads, they are for "installing" a thread in sheet steel.  For replacing damaged threads you would be better off using a threaded insert.  More expensive but more reliable.  I've used them in engine blocks for head bolts.

Hope I'm not teaching my grandmar to suck eggs.
Title: Re: Phils 4thirty build
Post by: Phils99 on March 09, 2014, 08:11:24 PM
yea cheers mate, but it was only a bracket to hold a wire so I thought I would repair it that way!
Title: Re: Phils 4thirty build
Post by: Furrari on March 09, 2014, 08:23:13 PM
Didn't mean to interfear but I thought I had better say.  I hope if I am not doing things the best way somebody tells me.  It's easier to learn by somebody else's experience than make your own mistakes.

M
Title: Re: Phils 4thirty build
Post by: Paul79 on March 09, 2014, 09:26:19 PM
Well done Phil. I know what you mean about the little jobs and how it looks like you don't get much further. But as you know, all these little brackets etc... It all goes towards making a much more solid car. You're right about the rear light brackets. Just having 2 out of the 3 bolts done up is enough I reckon. I just was on a roll so did all 4.  ;D and you know how I like my b&q brackets. Lol.
Title: Re: Phils 4thirty build
Post by: MADMAN on March 09, 2014, 10:17:16 PM
Had a nice "summers" day in the garage today...what great weather!

Pic 1. Finally painted up and reassembled the rear hub and brakes at last!

Pic 2. I thought I would invest in a Rivnut gut and a bunch of rivnuts, as I decided, like cheats to make my rear diffuser so you should be able to remove it without having to take the wheel arch liners out to hold the nuts whilst you unscrew the allen bolts, so I make a few plates and inserted a rivnut into them

Pic 3. I then bolted the diffuser on using these plates on both sides (passenger side shown)

Pic 4. I then added some Sikaflex and tightened up the bolts to dry on both sides (drivers side shown)

Pic 5. I also make some extra brackets for the rear lights, I decided that just 1 will be enough as they are pretty well solid with these 2 bolts on both sides (passenger side shown)

Pic 6. and then bonded these on by applying Sikaflex then tightening them up (drivers side shown) ..sorry the photo came out blurred

Pic 7. I also make brackets for the rear light....

Pic 8. ...and bonded these in place

continued.....







Hey Phil, you had a nice summers day in garage today, I had a nice summers day driving round in the nice sunshine.
I,m telling lies really, I had too much work to do in garden. :'(
MADMAN
Title: Re: Phils 4thirty build
Post by: rudycob1 on March 09, 2014, 10:42:29 PM
Great work Phil.
Title: Re: Phils 4thirty build
Post by: cheets on March 09, 2014, 11:43:46 PM
Nice work Phil and no i don't mind at all glad i have help you i love my rive nut :) for were you have the flex in the rear deck i stuck some box in i will post a pic to morrow as can not find the pic of it right know
Title: Re: Phils 4thirty build
Post by: cheets on March 10, 2014, 07:32:48 PM
Hi Pics for flex on rear dek

The bolts are puling on the on the box straitening the rear dek and taking out the flexes ones the sikerflexs has ton off i will take out the bolts

Hope this makes sense

Mark
Title: Re: Phils 4thirty build
Post by: Phils99 on March 10, 2014, 08:03:41 PM
nice one!!
Title: Re: Phils 4thirty build
Post by: Phils99 on March 14, 2014, 07:48:02 PM
Here is a little job you can do indoors!

take your hella headlights and the back plate (the one with the three large holes in) into your house and do the following:

Pic 1, remove all four screws and screw 3 of them back in, that is the 2 bottom ones (bottom is the way the main light connector is facing) and on one light the top left corner and the other the top right corner. screw them in about this far.

Pic 2, Drivers side should look like this with all 3 screws in, passenger side the single screw should be on the other side

Pic3, take 3 of the supplied plastic caps and snap them onto the head of the screws

pic 4, Pic 5, now clip the back plate onto the 3 plastic caps

pic 6, do the same for the other light and they should end up like this, the drivers side light is on the right, it will need the corner where you didnt use the screw cutting off before it will fit into the light housing.
Title: Re: Phils 4thirty build
Post by: johnjames on March 14, 2014, 09:31:55 PM
Hi Phils nice build great to read your article about headlights took my 430 out last night drove down a b road and could not see a thing the dip lights were shining just in front of the car and full lights were shining at the side of the car up in the trees the only way i could carry on driving was to let someone overtake and follow them on a scale from 1 to 10 I think my lights were about 3 when i set the lights up they were okay side LEDs were okay now only a few of the LEDs are working so it's great that you are talking about headlights like I said great build keep up the good work hope to see you at Stoneleigh J J
Title: Re: Phils 4thirty build
Post by: Phils99 on March 14, 2014, 09:55:22 PM
Whoa JJ!

What happened?

sounds like the lights have worked loose on the mounting brackets.

If you pop the front wheels off and the front arch liners you should be able to see whats going on!!

Hope its all OK and let us know what happened.

Looking forward to Stoneleigh and meeting all these new people I havent met yet! and seeing all these great cars!

This club is growing year on year...we are gunna need bigger pitches at all the shows!!
Title: Re: Phils 4thirty build
Post by: Lord Beany on March 14, 2014, 10:22:00 PM
Mine went out of alignment because I didn't drill through the two dimples on the rear of the light mounting platform and add screws to fix it in the correct position. I had secured the back end with a nut and bolt which worked loose over time.

Straightened it back up, tightened the bolt, drilled through the dimples and added a couple technology screws.

Problem sorted.

Hope yours is as easy a fix JJ.

Beany
Title: Re: Phils 4thirty build
Post by: MADMAN on March 14, 2014, 10:28:38 PM
Quatroroy has it all sorted,
he wears one of those headlight torches, even at shows ;D
sorry Roy couldnt resist that, well it was dark and we had drunk quite a few beers at Newark ;D
MADMAN ;)
Title: Re: Phils 4thirty build
Post by: Phils99 on March 15, 2014, 10:16:40 AM
hahahahahah I remember that night! brilliant!!
Title: Re: Phils 4thirty build
Post by: tenpin on March 15, 2014, 03:14:15 PM
.....
This club is growing year on year...we are gunna need bigger pitches at all the shows!!


I'll happily request larger pitches provided people let me know who's coming on the appropriate show threads (though most times I have to guess, because you have to book so far in advance!)

 - tenpin
Title: Re: Phils 4thirty build
Post by: Phils99 on March 16, 2014, 08:08:43 PM
So today was an "electrical" day for me, I thought I would have a change from bodywork!

I had previosly "made off" my rear superseal connectors indoors over a couple of nights, so all I needed to do was cut off the existing rear light plug and connect all my wires to the MR2 wires.

FIRSTLY DISCONNECT THE BATTERY THIS WILL STOP FUSES GETTING BLOWN!!

Pic 1, I now cut the MR2 plug off, this picture shows existing wires with plug cut off
 
Pic 2, I then twist my wires to the MR2 ones and put a bit of insulation tape over them, this pic shows all my wires connected to the MR2 wires just to test them

Pic 3, I reconnected the battery and turned everything I could on, even jamming something on the brake pedal to test, this pic shows all lights working on first time!!

Pic 4, After testing connections sucessfully, I disconnect the battery again, disconnect all wires and then slide on a piece of shrink cover, reconnect the wires, solder them together and then heat up the shrink cover over them.

Pic 5, I now nicely wrap all the wires together with insulation tape.

Pic 6, I then did the exact same on the other side and tested all the rear lights! All working well!

Pic 7, Here is the wiring for a Pre Facelift MR2, see Pauls thread for the facelift wiring.

Title: Re: Phils 4thirty build
Post by: Phils99 on March 16, 2014, 08:28:55 PM
I then moved onto the side indicators. Now DNA tell you to cut off the superseal and use it for the High beam on rhe headlight, well I didnt want to do this, so I purchases 5 x 2 pin superseal plug and sockets.

This meant that I can use 2 of the plugs on my high beam headlights and use 2 of the sockets on my side indicators! muck better so the side indicators and easily removable now.

Pic 1, shows the connected fitted for the side indicators

I then started on the high level brake light, for this I use 2 more of my superseal plug and sockets to add the brake light flasher unit. This means that if I need to remove it to replace or for MOT (?) then its just a matter of removing it and plugging the 2 wires for the brake light together without the flasher unit.

Pic 2, shows brake light connected directly

Pic 3, shows flasher unit in between

Pic 4, shows hole drilled in rear end for the brake light wire

Pic 5, brake light wire threaded through and coiled up ready

Title: Re: Phils 4thirty build
Post by: Paul79 on March 16, 2014, 09:32:25 PM
Well done matey. That's a big job out of the way. Next the headlights!
Title: Re: Phils 4thirty build
Post by: beemaman on March 16, 2014, 09:41:37 PM
well done phil getting closer like paul did it will make fitting up a lot easier when the glossy red paints on :)
Title: Re: Phils 4thirty build
Post by: cheets on March 16, 2014, 11:14:29 PM
Liking the work Phil just one thing what plug go was on the end of the cable for the brake light ?
Title: Re: Phils 4thirty build
Post by: Paul79 on March 17, 2014, 07:39:01 AM
Yes, good point Mark - Phil, did you managed to get a correct connector for the 3rd brake light? i couldn't find one, and i have used small spade connectors for now  :-[
Title: Re: Phils 4thirty build
Post by: Phils99 on March 17, 2014, 08:40:47 AM
for the 3rd brake light, I tested with 2 small spades....last night I was googling tring to find a plug, but I cant understand why its so hard! Hella are very popular and its know as the "hella brake light harness" I have the code number but could not find anyone selling them!
its the same with the headlight plug, I have the code number, but cannot find one for sale.

I have bought 2 different sets of Hid ballast connectors and although the plug looks similar to the headlight socket, they dont fit....I may wait for the kitcar shows and see if any of the stalls have them.

Title: Re: Phils 4thirty build
Post by: Paul79 on March 17, 2014, 09:26:58 AM
that's  interesting Phil, the HID Ballast ones i got fitted perfectly... these are the ones it got...

http://www.ebay.co.uk/itm/200571620419?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649

they came from the USA but arrived in under a week.

yeah i know what you mean about the hella 3rd brake light plug.. very mysterious

Title: Re: Phils 4thirty build
Post by: Phils99 on March 17, 2014, 07:15:51 PM
£3.61!!!!!!!!!

ordered!!
Title: Re: Phils 4thirty build
Post by: Phils99 on March 21, 2014, 01:15:20 PM
QUESTION TO THE FORUM

Do the roof securing straps that are used to tighten the rear window when roof is up have to come through the rollbar surround slots above the rear bins?

i.e. could they be left inside the rear bins and secured in there?

Reason being is that I would like the rear bin lids to be clear without this strap going across them and its one less hole to cut in the rollbar surround!
Title: Re: Phils 4thirty build
Post by: Furrari on March 21, 2014, 01:41:16 PM
I think that with the tension you need on these straps you would be pushed to fix them inside the 'box.
Title: Re: Phils 4thirty build
Post by: Lord Beany on March 21, 2014, 04:50:09 PM
I think Furrari is right. You do need to pull down pretty hard on the straps to get them onto the press studs; not sure if you'd get the leverage to secure them in the storage area.

I do know where you're coming from though. It'd be nice to access the storage without having to release the straps. I have to slide my seats forward in order to secure the straps due to having the seat all the way back.

It's liveable though, the only time I really fill the storage space is when going to shows.

Something to consider would be the length of the strap also as when you fold the roof, the straps withdraw a fair way, maybe even as far as the press stud in the strap, so if the strap was shorter, it could prevent the roof from folding correctly.

Beany ;D
Title: Re: Phils 4thirty build
Post by: cheets on March 21, 2014, 05:38:04 PM
Something i was thinking about was having the strap come trow the roll bar cover and then going 90º to the back of the storage bin and then having it  attach by a ratchet to tension it

But it is just an idea have not really had a look to see wether it will work :) 
Title: Re: Phils 4thirty build
Post by: Phils99 on March 21, 2014, 08:34:40 PM
cheers for the info guys....I will check it out when I see one of your cars, im a long way off that part yet!
Title: Re: Phils 4thirty build
Post by: Lord Beany on March 21, 2014, 10:26:32 PM
I thought ratchet earlier when I was thinking about it. That would allow tensioning of the straps, the same length straps but with a shorter mounting length.

Could work.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on March 23, 2014, 08:50:38 PM
Pic 1, so, to start with this weekend, I built a garden box, as, whilst I am working away, I order stuff off tinterweb and when I have been getting home, the parcels have been hidden all around the outside of the house!!

Pic 2, one of the parcels was a replacement boot release as when my wheel fell off, it damaged the supplied one. these are standard MR2 bonnet releases (thanks for that info Madman!)

Pic 3, Today, I thought I would have a test of the boor release solenoids, so firstly, I drilled 2 holes and fitted rivnuts

Pic 4, I then fitted the bracket for the solenoid

Pic 5, ...and then the solenoid

I can now honestly say....it doesnt work! the solenoid doesnt have the power to release the catch  ;-( ah well, back to the standard design then!

So I thought I would start on the front bumper, as since moving, its been wrapped up in cloths and hasnt seen the light of day for a year!!

Pic 6, I firstly drilled holes in the splitter

Pic 7, then used this "template" to drill the holes in the bumper

Pic 8, and then bolted the splitter on the bumper

continued................



Title: Re: Phils 4thirty build
Post by: Phils99 on March 23, 2014, 08:58:19 PM
....continued

Pic 1, I then used a heat gun to shape the front bumper splash guide

Pic 2, I then used gaffa tape to hold it in place so it was central

Pic 3, shows the holes drilled through the fibre glass and the plastic

Pic 4, Pic 5, I added a rivnut to each hole in the plastic

Pic 6, Now fitted with nuts, I will get some flat headed nuts when I finally fit it

Pic 7, shows the template made for the front bumper grill

continued....

Title: Re: Phils 4thirty build
Post by: Phils99 on March 23, 2014, 09:04:43 PM
...continued

Pic 1, shows mesh fitted around the hole ready to sikaflex on after paint

Pic 2, view of the mesh from the front

I then thought I would address the exhaust again, as im not happy with the fitting, so I noticed a bracket above the exhaust, so I bent it down a bit and then fitted the exhaust upper holding bracket to it, this allows me to push the pipe towards the rear of the car more so the pipe isnt touching the car body (which it was!)

Pic 3, shows the rubber exhaust hanger bolted to the bracket, just realised I didnt take a pic of the exhaust bracket installed, but its the one with the long thread welded to it, it now fits nicely in this hanger and allows adjustment.

Pic 4, the side hangers you get, just arent long enough and so make the exhaust have a slight angle when looked at from the rear, so I decided to make my own bracket as shown. This uses the supplied "L" bracket with a washer welded on to it and the standard exhaust hanging rubber. I have just used a large bolt and a metal plate and then drilled 2 holes in the bar for the U bolt to fit. This solution gives a little left and right movement of the end tips now so thats good. I also think that I will be able to get the U bends far enough in so that they will clear the arch liners.

I still cannot get these things lined up!...so when I get annoyed with something, I leave it and move on to something else...

I thought I would work on the rear inner wheel arch liners, so, following Pauls build, I got out the heat gun again and bent the tabs 90 degrees upwards, except the short long tab at the bottem, I bent that 90 degrees downwards.

I then fitted the drivers side liner in the wheel arch, and it fits pretty well without any cutting! The only thing is that as Pic 5 shows, I have a gap, now I guess I could pull the liner to cover that gap, but it fits so nicely, I think I will just cover it with some plastic seperately.

Pic 6, shows passenger side...couldnt seem to get a decent photo, but again, this fits very snuggly with no cutting! it also covers the area that is exposed on the drivers side so thats good.

I havent bothered bolting these in as I will do that after paint.

Well thats it for this weekend.....all these not very noticable but esential jobs now done, which is great.
Title: Re: Phils 4thirty build
Post by: cheets on March 23, 2014, 09:41:28 PM
Hi Phil looking the work have a look at this it shud have the power to open i have got the 80 for my doars and will be getting some of rheas for my rear deck

http://www.ebay.co.uk/itm/75-LB-Shaved-Door-Handle-Popper-Solenoid-Kit-Mini-Truck-685-/121220574065?pt=Motors_Car_Truck_Parts_Accessories&hash=item1c394f2b71
Title: Re: Phils 4thirty build
Post by: rudycob1 on March 23, 2014, 10:22:06 PM
Great progress mate.
It will be in the spray shop soon.
See you soon.
Title: Re: Phils 4thirty build
Post by: Phils99 on March 23, 2014, 11:12:03 PM
cheets..
75 pounds pulling power!!!!!!!

Mine were 5 pounds, I recon 10 would probably do it!
Title: Re: Phils 4thirty build
Post by: Phils99 on March 24, 2014, 04:46:58 PM
just realised, mine were 5Kg so around 11 pounds......
Title: Re: Phils 4thirty build
Post by: cheets on March 24, 2014, 05:50:42 PM
This is what i have go of my doors but will be getting to more for the rear deck
Title: Re: Phils 4thirty build
Post by: Phils99 on March 30, 2014, 11:37:36 PM
had sometime on the car this saturday and managed to get the following done....

Pic 1, I purchased these from Toolstation, gunna use these where I am bolting the under body plastics to the fibre glass as they have a large head with a low profile...and they work well with the rivnuts!!

Pic 2, Replaced all of the bolts I had secured the front bumper plastic on with the new ones...

Pic 3, I needed to cut out the front bumper rear air intakes so time to get the power file out again!!

Pic 4 and Pic 5, This is the bit that needs removing, if you look closely a faint moulded line exists so you know where you need to cut, I went over this line with a pencil and then back trimmed the first side of it as shown in pic 5

Pic 6 and here is the cut out after a little sanding to smooth it a bit

Pic 7, I then used the supplied mesh to make the shape, this is a very twisty shape, but the finer mesh can be manipulated, it takes a few goes to get it right, but just keep at it until it lays on the area correctly, here it is from the rear (hammer is just holding it on!)

Pic 8, from the outside

continued..........
Title: Re: Phils 4thirty build
Post by: Phils99 on March 30, 2014, 11:44:02 PM
...continued

Pic 1, Here are the templates for the upper air intakes and the markings I have put on for the way the mesh should lay, you need to get this right as you dont want "squares" you want "diamonds"

Pic 2, Here is one of them cut out, now I left a good bit of excess to "fold" over  when fitting, but this mesh is tough and is hard to fold, anyway, I found when folded, the pod that fits behind the mesh wouldnt fit correctly, so i trimmed them to just a bit bigger than the hole

Pic 3, Mesh fitted

Pic 4, I then cut out and trial fitted the rear sill mesh

Pic 5 and Pic 6, out with the rivnut gun again, and added a couple to the rear wheel liner ends.
Title: Re: Phils 4thirty build
Post by: cheets on March 30, 2014, 11:55:15 PM
Looking good Phil something i did with the rive nuts on the plastic were the rive nut was puling the plastic i put a washer on so it was puling on something solid

I have had a look throw my pic but not got one of what i men
Title: Re: Phils 4thirty build
Post by: Phils99 on March 31, 2014, 08:53:04 AM
Cheets, I think iknow what you mean, but I have found that the plastic is pretty stiff and seems to hold the rivnuts well....time will tell I guess!
Title: Re: Phils 4thirty build
Post by: ghall164 on March 31, 2014, 11:33:11 AM
Coming along nicely Phil  ;)
Title: Re: Phils 4thirty build
Post by: Phils99 on March 31, 2014, 02:10:28 PM
cheers ghall

its all these "little" jobs that take all the time but dont seem cosmetically to achieve that much in the build!
im also shying away from lining up the roll bar surround and the exhausts as they are doing my head in!

I need to get the exhausts done, as I want to refit the rear wheels so that I can pull it back to work on the front bumper!
Title: Re: Phils 4thirty build
Post by: MADMAN on March 31, 2014, 10:39:48 PM
cheers ghall

its all these "little" jobs that take all the time but dont seem conmetically to achieve that much in the build!

im also shying away from lining up the roll bar surround and the exhausts as they are doing my head in!

I need to get the exhausts done, as I want to refit the rear wheels so that I can pull it back to work on the front bumper!
             refit the rear wheels, what can I say :o I just had a flashback ;D
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on April 01, 2014, 08:34:56 AM
I do every time I go near that rear hub!! Jeez...imagine if it had have come off at 70 MPH on the A1!!
I was soooooo lucky, and to have my own personal recovery service just 10 mins away!! fantastic!

Hub all replaced now, I will put the spacers back on soon WITH 4 WHEEL NUTS this time!!
Title: Re: Phils 4thirty build
Post by: Lord Beany on April 01, 2014, 09:26:56 PM
And don't forget the loctite, Phil.

I've just had all four corners off mine to replace all the discs, everything was tight as a nut :-\ for want of a phrase after plenty of miles over two years or so.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on April 01, 2014, 09:55:13 PM
Im just wondering if I should do it now? Will i be sending the car to paint with the wheels on?

I guess I will, as my wheels need a bit of work on them (got them cheaper from DNA as I prefer these wheels....)

I am also still considering the aero kit and car then painted in Haaman style including rear spoiler I.e the aero parts are all black against a red car, also the front air intakes are all red, front splitter in black and the rear diffuser is red with black fins... as I dont think anyone has done that yet....google "red ferrari f430 haaman" if you want to see what I mean....and yes I know you should also have 20" wheels to complete the look....
Title: Re: Phils 4thirty build
Post by: rudycob1 on April 01, 2014, 10:16:24 PM
Phil, I think the Hamann style will look great. I was considering it at one point.
Like you said, nobody has done that yet.
You also have the wheels to finish the look.
Cannot wait to see you driving it mate.
See you soon.
Title: Re: Phils 4thirty build
Post by: Phils99 on April 06, 2014, 08:13:45 PM
another day, some more jobs done!

Started the test fit of my Ferrari script onto the rear deck, looking at the script and the pins, on mine, it would be very difficult to get the pin caps (sent to me by Paul, cheers mate) onto the 2 outer pins, so I make the decision to do a mixture of pin and cap and glue. I will cap the middle pin, but remove the two outer pins and glue the script to stop it twisting, shouldnt need much that way as the pin and cap will stop it falling off!

Pic 1, Shows me marking out on masking tape where the top metal ends under the deck. I then found the centre, but noticed that my centre pin is slightly off centre of the left to right measurement, so looking closely in the pic you will see the centre line and the hole for the pin just slightly to the left of the line.

Pic 2, shows the outer pins removed

Pic 3, shows the test fit, it lines up nicely in the centre of the deck, as I measured from both sides to check!

Next, was the "T" pieces used to secure the soft top at the rear, as I hadnt done these yet

Pic 4, shows the slot initially drilled, these holes are then joined and filed to create a slot the T piece will fit in

Pic 5, shows the T piece inserted, I had to pad it out with a thick washer as, on the passenger side, the T piece was touching the fibre glass underneath without it

Pic 6, Shows the thumbnut fitted, you get 4 of these, but you cant get them both onto the threads as they are too close to each other, anyway, 1 will be enough to hold it

Next, I had received a big bag of tie-wrap cable trees, so now I could tidy up all my wiring

Pic 7, shows the rear lights wiring tidied up with tie wraps on trees and well away from the exhaust pipes

Pic 8, Shows my third brake light flasher which is removable for MOT or can be bypassed if it stops working using the plugs.

Continued......

Title: Re: Phils 4thirty build
Post by: Phils99 on April 06, 2014, 08:28:21 PM
...continued

Next, It was time to remove the rear brace bar, I would have liked to keep this, but I think it gets in the way of the fake engine laying flat so it has to go (couldnt see any other reason for it to be removed?)

Pic 1, shows one end cut off

Pic 2, shows it now removed

I then wanted to make sure my alarm system still worked, the original position for the rear engine cover switch is obviously now useless, but, like Beany did, I found that just above the battery is a place where it will fit and work with the DNA frame. For this, you need to reshape the alarm switch bracket as shown below.

Pic 3, you will need to cut out a slot like this, this is found by holding the alarm switch bracket against the firewall and marking the fibreglass where it will need to be removed

Pic 4, the bracket has a lower lip below the bolt hole, flatten this out using a hammer, it flattens pretty easily

Pic 5 and pic 6, where the lip has now been flattened, make a 90 degree bend as shown on the left in this pic. You will also need a couple of bends in the longer straighter part to raise the switch nearer the frame and to also allow the wiring plug to not touch the battery, this will just be trial and error until it sits right, I was lucky and got it right first time!

Pic 7, now drill two holes in the end of the bracket to mount against the firewall

Pic 8, get yer rivnut tool out and drill 2 holes in the firewall and insert rivnuts

Continued.....
Title: Re: Phils 4thirty build
Post by: Phils99 on April 06, 2014, 08:42:13 PM
...continued

Pic 1, shows alarm switch now fitted and bolted in place

Pic 2 shows it working with the rear deck, this part of the rear deck is very thin, so I will look for something to make this area larger and flat, but at the moment it works well

I then run the wirng for the rear number plate lights and found that I would only need to lengthen one of the number plate lights as the other one reached

Pic 3, number plate light lengthened using the twist together/solder/shrinkwrap method, this was then taped up

pic 4, new wiring in place with the tie wrap cable trees and as I want them

I took delivery of the new more powerful solenoids from USA, BE WARNED I got HAMMERED for excise duty on these, as they them in two parcels, so HM custome added £11.99 to EACH parcel, the Post Offcie then added another £8 to EACH parcel as an admin chaged as they need to collect the HM customs money, and then the local post office added £1 to allow me to pay them! JESUS! the card through my door said, "To collect your parcels, please pay the sum of £39!!
These better work!

Pic 5, shows the new 75lb solenoid against a 5kg one, these are massive!

I had a look around to see where I could fit these, but couldnt see anywhere at this time which would be accessible to install them to, I will leave these for another day....

I then messed around with the exhaust surrounds and, like Others on here, found that they are a poor fit and need a lot of work, I had to remove most of the outside edge of the surround, but even then they will need some filler to make them better...again, a job for another day

Pic 6 shows the surround with the edge removed

Thats all for today.....
Title: Re: Phils 4thirty build
Post by: Paul79 on April 06, 2014, 08:51:18 PM
Good days work mate. Getting there. So is the 3rd brake light flasher MOT fail then? If so I'd better make mine remove able. Yes the exhaust surround need a bit of work I'm afraid.
Title: Re: Phils 4thirty build
Post by: Furrari on April 06, 2014, 11:47:02 PM
Paul
I was told that 3rd brake light flasher was legal, and there was even talk of making it compulsory on new cars.
I wouldn't remove it, just add a bypass switch

M
Title: Re: Phils 4thirty build
Post by: Paul79 on April 07, 2014, 10:03:00 AM
for a bypass switch do you mean splice another wire into the live wire and connect up to avoid the flasher unit, and then cut this wire and add a switch?
Title: Re: Phils 4thirty build
Post by: Phils99 on April 07, 2014, 10:19:00 AM
that was it, I wasnt sure if it was legal or not, so for the sake of two plugs, its removable if need be.

Monster, if your reading this, do you know if the flashing 3rd brake light is legal?
Title: Re: Phils 4thirty build
Post by: Furrari on April 07, 2014, 10:24:31 AM
Phil.
That's a better idea than a switch.  If there's no unit there can be no objection.
Title: Re: Phils 4thirty build
Post by: Wizard on April 07, 2014, 12:36:29 PM
The last time I looked the PG9 manual stated that the brake light must be a solid red (not flashing). I will look into it tomorrow unless Monster can answer this.

I seem to recall that pedal cycles can't have a rear flashing light unless there is also a solid rear light aswell.

Based on the pedal cycle rule the cars third light may have been changed but I will try to get the answer tomorrow.
Title: Re: Phils 4thirty build
Post by: Phils99 on April 07, 2014, 01:39:15 PM
thanks Wizard
Title: Re: Phils 4thirty build
Post by: Lord Beany on April 07, 2014, 04:35:49 PM
MOT this morning, passed with flashing third brake light.

Emissions on the 1MZ-FE vvti, were also well below the standard, and my rebuilt rear calipers, new discs pads and braided hoses were, "Very efficient"

Remembering the attention these cars get now. Lol.

Beany ;D
Title: Re: Phils 4thirty build
Post by: ghall164 on April 07, 2014, 04:49:58 PM
Nice work beany but was there ever any doubt with all the love and attention she receives from you she's allways in top fettle  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on April 07, 2014, 05:39:07 PM
good to know....but just like the HID headlight issue (i.e. MOT says that IF FITTED, self levelling must work whereas the law states that HID's MUST have washers and self levelling fitted), so you can pass an MOT, but still be done by the police.

This site explains all about the HID's

http://hid.moonfruit.com/# (http://hid.moonfruit.com/#)
Title: Re: Phils 4thirty build
Post by: Wizard on April 08, 2014, 09:40:57 AM
Phil, from what I understand you are not allowed to have a flashing break light.

Regulation 13 Road Vehicles Lighting Regulations 1989

Lamps to show a steady light

No vehicle shall be fitted with a lamp which automatically emits a flashing light except:

(a) a direction indicator;
(b) a headlamp fitted to an emergency vehicle;
(c) a warning beacon or special warning lamp;
(d) a lamp or illuminated sign fitted to a vehicle used for police purposes;
(e) a green warning lamp used as an anti-lock brake indicator;
(f)lamps forming part of a traffic sign

Or

A front of rear position lamp capable of emitting a flashing light when is fitted to a pedal cycle; or a trailer drawn by, or a sidecar attached to, a pedal cycle.

Hope this helps.

Wizard
Title: Re: Phils 4thirty build
Post by: Phils99 on April 08, 2014, 09:54:59 AM
 :( :( :( :(
Title: Re: Phils 4thirty build
Post by: Phils99 on April 13, 2014, 07:35:00 PM
so, I thought i would have a go at the rear deck release solenoid to test the strength to see if it would work.

The hardest part is finding somewhere to mount it that is solid as these are powerful things!, the best place I found was under the rear wing, just forward of the roof "drains"

Pic 1, here I have taped the mounting bracket on (its upside down, but it doesnt matter) just so I can mark the holes

Pic 2, I then drilled these holes and picked up my trusty rivnut tool and fitted them in the holes

I then created a bracket to be fitted under the mounting bracket, this will hold the adjustable end of the cable

Pic 3, shows the solenoid on the bench with the bracket laid under

Pic 4, this was all then bolted together using the rivnuts with a wire connected to the terminal, I had also threaded a spare release cable I has with a soldered on nipple through the end of the solenoid and ran this through to the rear deck lock as I have done for the emergency release.

I then closed the rear deck fully down (2 clicks) and touched the wire to the battery...BINGO! it unlocked the deck! At last, go it working.

So I will probably do the other side another day as I didnt have another cable with a soldered nipple on and I will then wire these through relays and back to a switch I have that will replace the existing boot/petrol release levers (as I plan to make the petrol flap release with a solenoid as well!), I will also wire these through the handbrake warning switch so that they ONLY work when the handbrake is on, i.e. car is stopped.

I then decided to finish off the rear deck bonding.

Pic 5, The part I hadnt yet done is the bit of the rear deck that is near the pops, this shows a bracket I made (like Paul did!) which is bolted to the metal and then bonded to the rear deck, I completed this on both sides, just these brackets took over an hour to do!

Front wing securing brackets

Pic 6, whilst in the "Sikaflex" mood, I also bonded these brackets to the front wings, I was totally confused that the passenger side had about a 1cm gap between the brackets and the headlight mounting bracket yet the drivers side lined up nicely!, then I realised, the headlight mounting bracket can be bent slightly up to meet the securing brackets....
Title: Re: Phils 4thirty build
Post by: beemaman on April 13, 2014, 08:05:10 PM
Looking good phil love the solanoids :)
Title: Re: Phils 4thirty build
Post by: rudycob1 on April 13, 2014, 08:20:07 PM
Great work mate.
Title: Re: Phils 4thirty build
Post by: Paul79 on April 13, 2014, 10:28:42 PM
Good days work matey. I remember DNA saying about those brackets and how some might need adjustment or mounting from on top or underneath the metal of the headlight carrier  bracket.   But it doesn't matter as long as they are there.  ;D.
Title: Re: Phils 4thirty build
Post by: Phils99 on April 20, 2014, 05:20:40 PM
Another day - some more tasks ticked off the list!

Firstly, I have now recieved my K&N filter kit, so I fitted this first, I dont need to detail this too much as it comes with great instructions and pictures and you can download the installation doc from K&N if you want to read throught it before you pruchase (like I did!)

Pic 1, Here is what is in the kit, it really contains everything you will need, pretty good really!

Pic 2, Remove the old air filter and the box

Pic 3, here you bolt on an extension piece of heat shield to the existing piece

Pic 4, As I said the kit contains everything, including a P bracket like this to tidy up the existing pipes that used to clip to the old airbox

Pic 5, here is a special bracket to support the air intake hose from the engine

Pic 6, Whilst I had the MAF out, I also sprayed it with carb cleaner to clean it up

Pic 7, The air filter and MAF holding pipe are then inserted into the air intake from the engine and tightened up

...continued

Title: Re: Phils 4thirty build
Post by: Phils99 on April 20, 2014, 05:34:35 PM
...continued

I then took the supplied expandable hose and run it from the air intake pod on the passenger side to the air filter

Pic 1, securing the pipe under the rear wing

Pic 2, pipe run to the air intake pod, and unbelievably, it fits perfectly inside the pod!!

Pic 3, I added some heat reflecting tape to the back of my rear wheel arches, I also sikaflexed connecting blocks inside the rear wheel arch lip, but I didnt get a picture of this :-(
, I will refit the rear wheel arches probably tomorrow when the sikaflex is dry

Pic 4 I then cut out the mesh for the rear deck, same way as before, make a cardboard template and cut round, I did this twice and then just turned one mesh over and I had both sides then done.


....continued
Title: Re: Phils 4thirty build
Post by: Phils99 on April 20, 2014, 05:49:09 PM
...continued

I then started work on the front cover plate above the radiator

Pic 1, This required removing old fixing brackets (arrowed) to allow the cover to sit at an angle down to the front clip.

Pic 2, Like Pauls build, the cover fits better if you cut out these parts to fit round the radiator braclets

Pic 3, I then scribed with a stanley knife a line and using a heat gun, I put a bend in the cover so that it sits better on the front clip, I also drilled holes where the fixings would go

Pic 4, I then dug out 2 of the original fixings, the one where you push the pin in the middle down a click to remove and found these wouldnt fit correctly, so I dug around and found bigger versions of the same fixings, they are longer and now clip it all together nicely

Pic 5, front cover fitted, I think I will use some sticky velcro to hold the front edge down, but I will fit that after paint

Pic 6, I also fitted and tightened up the bolts for the headlight carrier to the front wings as I had bonded these on previously

I also thought its was now time to strip the interior, so I removed the seats, interior plastics and the carpet and stored them away.

I plan to also work on it tomorrow so prepare for another update later!
Title: Re: Phils 4thirty build
Post by: MADMAN on April 20, 2014, 11:11:55 PM
another good day on your build and same monday, at this rate it will soon be finished and lining up next to the mr2,s with your own proximity alarm ;D
see you at the weekend
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on April 28, 2014, 01:57:33 PM
I have now just managed to buy a REAL f430 centre console which is a bit dirty, but thats no worries as I would be recovering it anyway!...so I will try to fit this is, it maybe too wide, but ill see.

Ive also just won a real f430 ashtray including the crossed flags to fit in the centre console!!

May save me trying to build one!
Title: Re: Phils 4thirty build
Post by: MADMAN on April 28, 2014, 02:17:02 PM
Nice one m8,
If it,s too wide i,m sure it can chopped to make it fit
MADMAN
Title: Re: Phils 4thirty build
Post by: Phils99 on April 28, 2014, 03:36:25 PM
fingers crossed, but yes, I can chop a bit out of the middle!
Title: Re: Phils 4thirty build
Post by: Phils99 on April 28, 2014, 04:22:35 PM
some pics...
Title: Re: Phils 4thirty build
Post by: ghall164 on April 28, 2014, 04:24:21 PM
 :) nice finds mate should really set off the interior she's coming along nicely ;D
Title: Re: Phils 4thirty build
Post by: rudycob1 on April 28, 2014, 06:01:48 PM
Great stuff mate.
Title: Re: Phils 4thirty build
Post by: Phils99 on May 03, 2014, 07:36:11 PM
update.

Pic 1, firstly, I wasnt happy with the headlight to wing brackets previously bonded with Sikaflex, so I removed them and rebonded with P40...MUCH stronger! I also had to pack the gap between wing bracket and headlight bracket, as, if I forced the bolt tight, it altered the wing near the door and made the door catch when opening!

Pic 2, next I re-addressed the pod retainer as, it needed more packing for it to work correctly, so it now has 2 bolts and a washer spacing it out

Pic 3, I also attached some twine, as its easier to pull using this then trying to get your hand inside, I will replace these with some nice straps when I find some.

Pic 4, I stripped out a few more interior parts

Pic 5, When I trial fitted the front air intake scoops, one of them wouldnt fit correctly, so, I thought I would try "bending" the fibre glass. This involved clamping it and then putting the part I wanted to bend under stress, I then used a heat gun front and back on this area to soften it, and then leave it under pressure to see if it would move.

Pic 6, I then trial fitted it again and it now fits much better!

Pic 7, I then moved onto the fake engine to get this to fit and the rear deck to close, you need to remove this triangle area

Pic 8, Like this

Continued.....
Title: Re: Phils 4thirty build
Post by: Phils99 on May 03, 2014, 07:44:30 PM
...continued

Pic 1, I then needed to remove this area to allow the deck to close

Pic 2, like this

Pic 3, this is so the rear deck clears at these areas, obviously I cut these parts out of both sides.

Pic 4, The fake engine then sits too long and goes inside the exhaust opening

Pic 5, so it needs to be trimmed along this line

Pic 6, Like so

Pic 7, I then sanded round the part where the rear glass fits so that it would fit better, so here it is! the fake engine under the glass!

Continued.....

Title: Re: Phils 4thirty build
Post by: ghall164 on May 03, 2014, 07:52:02 PM
 :) nicely done Phil  :)
Title: Re: Phils 4thirty build
Post by: Phils99 on May 03, 2014, 07:52:27 PM
One last job was to replace the rear engine strengthening bar, well the fake engine gets in the way, so a few options exist:
1. Cut out the area of the fake engine where the bar touches,
2. Remove the bar completely
3. lower the front of the bar so it doesnt touch the fake engine.

I chose option 3 as recommended by Madman as that is what he has done.

Pic 1, The brackets made and fitted and lowered the bar perfectly so it now doesnt touch the fake engine!

Pic 2, this pipe needs to be altered so its not in the way, its just a matter of turning the holding clips the other way round and a little bending of the pipe and it fits great!
Title: Re: Phils 4thirty build
Post by: Phils99 on May 08, 2014, 03:05:25 PM
QUESTION

What have you guys used over the large opening above the exhaust, the plate where you fix the hinges for the fake engine to?

Does it get very hot there?

Would thick plastic with heat reflector on do the trick?
Title: Re: Phils 4thirty build
Post by: beemaman on May 08, 2014, 03:23:32 PM
phil i used diebond its a metal type sheet i had left over and then i coverd it in carbon wrap and used black no plate screws and caps.i had no issues with it burning off etc and being metal it stayed flat and didnt warp.

also buddy use plastic hinges they wont rust and run rusty water everywere.
Title: Re: Phils 4thirty build
Post by: Phils99 on May 08, 2014, 04:27:59 PM
Cheers beemaman, I already bought the plastic hinges about 1 year ago after reading your original thread :-)
Title: Re: Phils 4thirty build
Post by: rudycob1 on May 08, 2014, 04:32:54 PM
I used a bit of Carbon Fibre sheet and no issues even with the heat from the V6.
Title: Re: Phils 4thirty build
Post by: Lord Beany on May 08, 2014, 07:00:19 PM
I recycled and used the old parcel shelf that the mr2 roof used to fold into.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on May 08, 2014, 09:16:55 PM
Cheers guys...any more?

beany, doesn't the heat melt the plastic?
Title: Re: Phils 4thirty build
Post by: MADMAN on May 08, 2014, 10:57:16 PM
Cheers guys...any more?

beany, doesn't the heat melt the plastic?
give me a ring or txt friday dinner, I may just have the piece you need (ex DNA) that I did not use
MADMAN ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on May 09, 2014, 08:20:53 AM
why am I not suprised ;-)
Title: Re: Phils 4thirty build
Post by: Phils99 on May 11, 2014, 08:18:33 PM
so...today I decided to tackle the 2 jobs I have been putting of for ages!

1. trial fitting the rear exhausts surrounds and making them better with filler (as I have NEVER used filler before!)
2. Lining up the rollbar surround

Pic 1, I fitted the surround as best as it would go, but it still left a large gap where the arrow is pointing

Pic 2, So I decided to trim the inner lip of the exhaust hole to see if that would help

Pic 3, It was a little better, but still not good enough for me.

Pic 4, So I removed the surround and taped up the edge where I was going to use filler

Pic 5, I removed the surround and keyed the area I was going to fill

Pic 6, I reattached the surround...

Pic 7, ..and then mixed up the P38...

Pic 8, and then filled in the gaps....
Title: Re: Phils 4thirty build
Post by: Paul79 on May 11, 2014, 08:20:14 PM
MATE you forget the pics!!!
Title: Re: Phils 4thirty build
Post by: Phils99 on May 11, 2014, 08:23:24 PM
lol!

your too quick! I hit post by mistake!!
Title: Re: Phils 4thirty build
Post by: Phils99 on May 11, 2014, 08:31:59 PM
Pic 1, I then removed the surround with the tape...

Pic 2, and pulled the tape off to leave the filler

Pic 3, Test fit...not bad! will look fine after paint

Pic 4, How it looks off the car

Pic 5, The other side wasnt as bad, but did need doing

Pic 6, I then did the exact same thing to the other side....

Title: Re: Phils 4thirty build
Post by: Phils99 on May 11, 2014, 08:43:56 PM
so, next job the roll bar surround....at Stoneleigh, when JJ opened his rear deck of the white 430, I noticed that the roll bar surround was held on with tek screws at the rear, so I thought I can use these to help straighten the surround up.

Pic 1, I worked out that I will need 3 thick washers between the rear of the surround and the metal frame at each side, BUT NON IN THE MIDDLE!!, to do this, I used some masking tape to hold 3 washers together.

Pic 2, and, after initially fitting the tek screw into the frame by drilling a small pilot hole first, I then inserted the 3 washers and did this at both ends

Pic 3, So I had a screw at each end and one in the middle...

Pic 4, SUCCESS!! I now have a very straight gap between the surround and the rear deck!

Pic 5, Though I would finish off a few other little jobs....I fitted an earth wire to the petrol filler

Pic 6, and then painted it up

Pic 7, I also then painted a few other brackets I hadnt done yet.....

Pic 8, and also "key" alined my rear hinges
Title: Re: Phils 4thirty build
Post by: Paul79 on May 11, 2014, 08:51:47 PM
glad you've finally got the roll bar surround sorted matey, you have been worrying about that. good to see the toolstation brackets are becoming legendary!!!
Title: Re: Phils 4thirty build
Post by: MADMAN on May 11, 2014, 08:56:40 PM
Hey Phil,
             did you or anyone else buy switchback leds from ebay yet? my leds are failing and want to replace them with switchbacks, Ther is a few on ebay just wondered if you could recomend any
MADMAN
Title: Re: Phils 4thirty build
Post by: Phils99 on May 11, 2014, 09:26:26 PM
Yep, I got these http://www.ebay.co.uk/itm/400673565484?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649 (http://www.ebay.co.uk/itm/400673565484?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649)

They work a treat!
but they are not like LEDs as they are more a light tube but I think they will look OK under the sidelight lens
Title: Re: Phils 4thirty build
Post by: Phils99 on May 11, 2014, 09:27:59 PM
Paul,

Toolstation and Robert Dyas...my 2 favorite shops!!
Title: Re: Phils 4thirty build
Post by: MADMAN on May 11, 2014, 09:38:59 PM
Yep, I got these http://www.ebay.co.uk/itm/400673565484?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649 (http://www.ebay.co.uk/itm/400673565484?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649)

They work a treat!
but they are not like LEDs as they are more a light tube but I think they will look OK under the sidelight lens
How are they for fit? do they fit into light tube length and width? can they be cut? or fold out of way?
cheers MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on May 11, 2014, 10:04:02 PM
I got the 60cm ones and they are about 8cm to long, but you can leave them tucked behind the light

I think they will fit under the lens.....if you wanna hang on, I can bring them next Sunday when I pop in for the dibond....
Title: Re: Phils 4thirty build
Post by: MADMAN on May 11, 2014, 10:42:34 PM
I got the 60cm ones and they are about 8cm to long, but you can leave them tucked behind the light

I think they will fit under the lens.....if you wanna hang on, I can bring them next Sunday when I pop in for the dibond....
     No worries I,ve ordered some, sh-t or bust ;D
see you next sunday, if I not in I will leave at side of my front door, but I will probably be in
MADMAN
Title: Re: Phils 4thirty build
Post by: Phils99 on May 12, 2014, 08:47:04 PM
I have managed to blag a few days workinh from home, so I managed to get a couple of hours on her tonight.

Decided I would fit the roll hoops, so, to start I needed to remove the roll bar surround and cut out the roof release catch opening.

Pic 1, here is the underneath of the surround, the hole to cut out is already marked, so I went over this with a pencil

Pic 2, initially I drilled holes and connected these up with a hand saw, I then used the power file to round off the edges and then sandpaper to finishe off

Pic 3, After testing the roof release catch, like Paul, I also found it was too deep to really get your fingers under the catch, so I added a couple of brackets to extend the catch out, this is now much easier to get your fingers under and open the catch with.

Now onto the roll hoops, they only go one way and one side, so make sure you get these right! One end has a drilled hole in that is threaded for a large bolt which I think is supplied, but I found them in my "bolts" box!

Pic 4, I fitted the bolt end loosely and then held the "foot" end in the centre of the cut out hole, I then used a large felt pen to mark the fixing slot in the metal surround holder onto the underside of the "foot"

Pic 5, shows the "foot" marked, I then drilled this out and then refitted to the car with a nut and bolt

Pic 6, repeat on the otherside and voila!!

Title: Re: Phils 4thirty build
Post by: Lord Beany on May 12, 2014, 09:32:57 PM
Ha, i didn't even realise there was markings for a cut out there. ::)

I don't use a catch, just stow the soft top and the rear deck and dummy engine hold it in place.

Beany  ;D
Title: Re: Phils 4thirty build
Post by: Furrari on May 12, 2014, 09:54:27 PM
The idea of the catch is to hold it away from the underside of the engine.  The roads around here are so bad that I had to cover the hood to stop it being marked by the engine as it all moved around.
Title: Re: Phils 4thirty build
Post by: rudycob1 on May 12, 2014, 11:06:45 PM
Phil
I turned the catch upside down and it's much easier to use once everything is put together and finished.
Title: Re: Phils 4thirty build
Post by: Phils99 on May 13, 2014, 08:25:14 AM
Beany, Furrari is correct, I wasnt going to use a catch then Madman told me the same thing, if its not locked down it will rub against the bottom of the fake engine and mark it.

Rudy, I had read about turning it upside down, but it didnt seem to make it better for me! Anyway, with the brackets its MUCH easier to open now....
Title: Re: Phils 4thirty build
Post by: Furrari on May 13, 2014, 10:16:57 AM
Phill,
Can't seem to get through on PM ref brakes.  I'll try again later.

Mick
Title: Re: Phils 4thirty build
Post by: Lord Beany on May 13, 2014, 08:38:03 PM
The access panel built into my car in order to access the front bank of cylinders on the v6 actually keeps the roof from folding in as flat as it used to, so when i close my rear deck everything gets sandwiched together with no movement at all.

I get the idea though.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on May 13, 2014, 09:08:35 PM
IS Z FLAP TIME  ;D ;D ;D

Had some time tonight, so I thought I would have a go at the Z flaps. Looking at many other builds, I decided to go with the kitchen hinge solution so that it doesnt get broken off!

Pic 1, shows the marking I have done for the cut out required.

Pic 2, shows the cut out you need in the existing roll hoop surround, this is quite a large amount and I think, like Madmans solution, I will probably add a strengthening bracket to the top part above where I have cut.

Pic 3, I then made this bracket from some old metal shelving I had and bolted it to the hinge

Pic 4, Hinge fitted to the rollbar metalwork, I moved the hinge in a little towards the bend in the bracket as it was catching with it mounted as in Pic 3, you can probably tell.

Pic 5, Z flap just held on with sticky tape to see what it looks like, I think it has come out pretty good!

Just need to bond the Z flap to the bracket and then do the other side, I will leave that until weekend.
Title: Re: Phils 4thirty build
Post by: Lord Beany on May 14, 2014, 03:44:41 PM
Make sure you test the roof raising past the flaps when they're folded away before you bond them, i had to tweak mine a couple times in order to get the clearance.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on May 14, 2014, 04:18:17 PM
already did and it cleared it OK!



Title: Re: Phils 4thirty build
Post by: johnjames on May 15, 2014, 12:11:09 AM
Hi Phil underneath my dummy engine cover I have glued a thin layer of rubber that fits over the top of the roof and that works okay like the idea of moving the clip that holds the roof, I done mine  today I did not use a metal bracket I used 2 longer bolts and some locking nuts but thank you for the good idea makes it a lot easier specially if you've got big fingers good luck with the build take care J J   8)
Title: Re: Phils 4thirty build
Post by: Phils99 on May 15, 2014, 08:40:55 AM
It was me "showing" you how to release your roof for you that made my mind up to alter mine!
Title: Re: Phils 4thirty build
Post by: Phils99 on May 23, 2014, 10:44:18 AM
Its quiet on here lately?

Thought I would post just to break the silence!

I did work on mine last saturday and will post the pics when I get home tonight.

I am hoping to get 2 if not 3 full days on it this weekend!

I am getting nearer the "ready for paint" each time I tick off outstanding "must do before paint" jobs...but I do keep adding to the list as I discover new things, i.e. I have just purchased 2 Original used Ferrari red door lights from Eurospares, £20 delivered! and will now need to fit these in before paint, here is my outstanding task list just for anyone who is interested:

[ ] key align bonnet hinges and rear deck hinges
[ ] fit and thread lock rear spacers
[ ] fit rear wheels
[ ] drain holes in rear bumper - need wheels on for level
[ ] wire up headlights - awaiting sidelight superseal plugs
[ ] fit twist brackets
[ ] Fit plastic bags over wiring
[ ] remove front wheels and swap discs over (as I put them on wrong sides!)
[ ] Thead lock front wheel spacers and refit front wheels
[ ] fill sills with foam
[ ] Fit front bumper
[ ] trial Fit front wheel arch liners
[ ] trial fit door cards
[ ] Trial fit door courtesy lights - the ones that shine ferrari symbol on the floor
[ ] drill drain holes in door
[ ] fit red lights in doors
[ ] trial fit door mirrors
[ ] put car on 4 stands and fit underbody brace
[ ] fit rear exhaust cover dibond plate
[ ] fit hinges to fake engine
[ ] Paint under all fibreglass black
[ ] trim seat belt covers plastic
[ ] wire up solenoids on rear deck
Title: Re: Phils 4thirty build
Post by: Paul79 on May 23, 2014, 12:23:39 PM
haha, yes it is a bit like the Mary Celeste at the moment  :)  i'll stick some pictures up later too. yes, the to-do list is getting shorter...it was a good couple of pages last time!
Title: Re: Phils 4thirty build
Post by: Phils99 on May 23, 2014, 07:31:58 PM
Bit late posting this, I did these things last Saturday...

I received my used Breast Plate on Saturday morning

Pic 1, show the used breast plate, had to laugh, for some reason I expected these to be huge and took my X5 to the post office to pick it up as I didnt think it would fit in my green machine! as you can see by the tape measure, they are not very big at all!!

Pic 2, a little sanding to get rid of any flaky paint

Pic 3, blathered in 2 coats of Hammerite black

Next I then fitted the wheel arch liners with some clips I had

Pic 4, I found these clips, not sure if they are off the MR2, but they are the "push in the middle to release" clips, I had enough of them to do both sides

Pic 5, I drilled the holes in the wheel arch liner tabs whilst its off the car

Pic 6, I then used the hole to mark the MR2 body and drill a hole in it for the clips, I then fitted the clips and they hold a treat!
Title: Re: Phils 4thirty build
Post by: Phils99 on May 23, 2014, 07:38:22 PM
I then worked on the other Z flap

Pic 1, firstly I needed to do a little sanding on the raised edge of the roll bar surround

Pic 2, I then marked 2 straight lines where I need to cut

Pic 3, then cut out the part

Pic 4, I then fabricated a plate just as I had done for the other side, here is a pic of the plate...

Pic 5, ..and this is the cabinet hinge mouted to it

Pic 6, Which was then lined up against the cut out, marked and two holes drilled so that the hinge can be mounted to the roll bar surround carrier.

Pic 7, and then tested so that it flips back and forward nicely.
Title: Re: Phils 4thirty build
Post by: Phils99 on May 23, 2014, 07:45:25 PM
I then wasnt happy with the lack of strength left in the roll bar surround after the cut out was done, so I made some brackets to strengthen them

Pic 1, This is the bracket I made for one side..

Pic 2, shows it fitted to support the surround (when bonded on)

Pic 3, and this is the other side.

Time to bond the Z flaps...

Pic 4, I took the hinge and bracket off and removed the paint from the metal

Pic 5, then bonded on one side...

Pic 6, ..and the other!

Pic 7, I then tested to make sure they clear the roof sides when clipped back...loads of room!
Title: Re: Phils 4thirty build
Post by: rudycob1 on May 23, 2014, 07:59:35 PM
Great work.
It will soon be a different colour mate.
It's so good to see you getting there and can't wait to see you driving over to mine in it  :)
Title: Re: Phils 4thirty build
Post by: Phils99 on May 23, 2014, 08:17:48 PM
looking forward to joining the yorkshire car show convoy in my own kit car!
Title: Re: Phils 4thirty build
Post by: MADMAN on May 23, 2014, 09:35:57 PM
A up Phil,
             on photo 175 under where you cut and there is not much fibreglass left I bent a welding rod and bonded it at the rear to help reinforce the fibreglass, hope this will save yours from breaking as mine did ::)
ill be great when you join the Yorkshire convoy in your F430 spider, but I for one will miss your mean green machine. You will have t advertise it on here for a future builder to run around in while building there dream car, or as a reliable doner
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Furrari on May 23, 2014, 09:59:30 PM
Oh no.  Not selling The Green Machine.  It's got to stay in the club, it's our Before.
Title: Re: Phils 4thirty build
Post by: Phils99 on May 23, 2014, 11:10:34 PM
If I could get my son interested, then he could drive the green machine down whilst I drive the 430!!

Im trying....
Title: Re: Phils 4thirty build
Post by: MADMAN on May 24, 2014, 12:03:22 AM
If I could get my son interested, then he could drive the green mach 8)ine down whilst I drive the 430!!

Im trying....
               He,s not interested :o Duck tape his hands to the steering wheel of the green machine and stick it on my A frame he will have to follow then ;D
MADMAN
Title: Re: Phils 4thirty build
Post by: Furrari on May 24, 2014, 11:23:31 AM
Not interested?  What does he have flowing through his veins?  :-(
Title: Re: Phils 4thirty build
Post by: Phils99 on May 24, 2014, 06:25:26 PM
had a great day on the car today, I completed some big tasks off the list, namely the removal and refit of the spacers with thread lock and the fitting for the very first time of the front bumper!

Pic 1, First of all I drilled a couple of 3mm holes in the hinges so that they can be aligned easily after removal and placed a nail in them as a "pin"

Pic 2, only one pic of this I its been detailed before in mine and other threads, but I removed both parts of the rear spacers and then refitted fully tightening them and added some thread lock as I dont want the wheels to fall off again!

Pic 3, LOL look at the difference in size of the 430 rear wheels and the MR2 standard ones!!

Pic 4, Rear wheels fitted for the first time in 7 months!!, dont worry about the gap above the wheel as I still have the axel stands underneath ready to fit the underbody brace plate...maybe tomorrow...

Pic 5, Rear wheels on, front wheels off!

Pic 6, Like Paul, to get the full tension on the front spacer fixing bolts, I decided to remove the hub and work on it on the bench. This give much better access to the bolt through the cut out section

Pic 7, As I am using threads instead of nuts for the front wheel, I needed to really tighten the threads into the spacer, I couldnt find any nuts to fit the threads, so I cut up a couple of the MR2 wheel nuts so, after applying some thread lock to the threads,  I could lock them together to then tighten them up.

Pic 8, All threads tightened nicely.....
Title: Re: Phils 4thirty build
Post by: Phils99 on May 24, 2014, 06:33:30 PM
Pic 1, .....and refitted to the car, I have tie wrapped the brake pipe to the suspension, is this what everyone else did? Anyone got a better solution.

Pic 2, Lining up the front bumper ready to fit, the marked out holes in the bumper for the mounting screw threads are pretty close to where they need to be, I only had to slightly enlarge one hole and they all fitted nicely.

Pic 3 and 4, looking through the headlight hole, you can see that the front bumper mounting brackets will not allow the bumper to be fitted without some modification, I have marked with a pencil where they need to be trimmed.

Pic 5 and 6, show the cut outs required for each side

Pic 7, Looking from underneath, it now fits nicely round the brackets!

Pic 8, and there she is with the front bumper fitted!!

Looking forward to getting back in the garage tomorrow.

Title: Re: Phils 4thirty build
Post by: MADMAN on May 24, 2014, 11:59:50 PM
Coming on in leaps and bounds Phil,
but looking at the time you posted this, I wonder if you have any lights in your garage if you had you could work on till the early hours  ;D ;D looking good m8 not long now. Love your wheels ;)
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on May 25, 2014, 10:13:59 AM
Cheers Madman,

im usually knackered by 6pm after a full day on the car!!
Title: Re: Phils 4thirty build
Post by: ghall164 on May 25, 2014, 03:32:16 PM
 ;D wow Phil your really cracking on now she's looking great  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on May 25, 2014, 07:31:14 PM
cheers ghall, its the pleasures of being single! I can spend as much time as I like in the garage!
Title: Re: Phils 4thirty build
Post by: Phils99 on May 25, 2014, 07:44:36 PM
So, another good day in the garage today, I tackled another job I wasnt looking forward to, mounting the underbody brace bar, as, I had read on MR2ROC forum, that a few people have sheared the bolts off whilst trying to remove them....amyway, I set about jacking the car up as high as I dare on my 4 axle stands so I could get under. I then slid under with a ratchet, pliers (to release the pipes that run in the tinnel from the existing brace bar), a long handle and a 12mm socket.
Firstly I inspected the nuts, and to me relief they all looked "unrusted"!!

Pic 1, these are the existing brackets that you remove, the large one is in the middle of the car and the small one at the rear.

Pic 2, the brace bar then does the job of both of these bars in one go!, it was so easy to fit and looks a treat.

Pic 3, I then filled the sills with expanding form to give them a little but more "body" (good idea Lord Beany!)

Pic 4, the other weekend I popped into Madmans and he gave me a piece of Dibond sheet to use to cover the exhaust opening, I cut this to shape (avoiding the area where the rear deck stops touch) and fitted using some nice flat head bolts, I intend to cover the board with carbon fibre wrap before fitting.

Pic 5, I then lined up the fake engine correctly and marked where the hinges would go on the fake engine and the Dibond board, removed the engine and drilled the holes for the hinges.

Pic 6, I then fitted the hinges

Pic 7, fake engine and hinges fitted to board

Pic 8, and it works!!
Title: Re: Phils 4thirty build
Post by: Phils99 on May 25, 2014, 08:04:33 PM
I then had a go at the front inner wheel liners, these are in 2 parts.

Pic 1, I started looking at this part (the front bit) and wondered why it had a large tab at the bottom?, I then realise that, when the liner is fitted leaving space for the wheel to turn, it lined up perfectly with the front bumper under liner!....

Pic 2, ...so that means bending the small tab downwards and the large tab upwards...

Pic 3, ..and get out the rivnut gun again and add 2 to the large tab

Pic 4, the thinner part of the liner has a cut out which goes where the front bumper meets the wing, but I found the cut out wasnt deep enough and didnt allow the liner to fit properly, so I marked up how much to remove...

Pic 5, and then cut it out, the liner then slotted in nicely after this little mod!

Pic 6, this brake sensor connector was in the way and stopping the front wheel liner from pushing further back, so I moved it to nearer the headlight, this allowed the liner to sit well out of the way of the wheel...

Pic 7, ...and so, I also added a small cutout on the right for the wire to go through, so this is both parts of the liner fitted, again, I have used a rivnut to connect the two liners together at the top and using the small tab on the left, I fixed this with one of those "push the pin in the centre" type of fixings

Pic 8, and this is the rear part of the front liner, I have added a small arrow if you are interested to blow up to see the fixing, I also added a flat bolt and nut at the bottom....
Title: Re: Phils 4thirty build
Post by: Phils99 on May 25, 2014, 08:08:41 PM
Pic 1, and here is a view from underneath where I have joined the front part of the wheel arch liner to the front bumper liner using the 2 rivnuts fitted earlier.

Pic 2, the big test! full lock with the wheels on...and plenty of clearance!!
Title: Re: Phils 4thirty build
Post by: Paul79 on May 25, 2014, 08:55:41 PM
you're on FIRE matey! Catching me up!!!  ;D Great work.
Title: Re: Phils 4thirty build
Post by: Phils99 on May 25, 2014, 10:18:40 PM
got a long way to go to catch you up buddy!!
Title: Re: Phils 4thirty build
Post by: ghall164 on May 26, 2014, 01:26:37 PM
 ;D sure does beat the list of bank holiday jobs my old lady has given me  ;)
Title: Re: Phils 4thirty build
Post by: Phils99 on May 26, 2014, 02:01:49 PM
yea...im really enjoying working on the car, love doing all these little jobs and each day getting nearer to the paint shop!

ah well, lunch over, back to the garage!!
Title: Re: Phils 4thirty build
Post by: Phils99 on May 26, 2014, 08:22:43 PM
Another very productive day, but not really much to take pictures of!!

I started by trial fitting the drivers front wheel arch liners, which were fitted identical to the passenger side (see yesterdays post).

When this was completed, I then removed the front wheel arch liners and the front bumper liner and stored them away for when the car has been painted.

I then removed the rear lights, rear reflectors, number plate lights, fake engine and exhaust cover board and also stored all these away for later.

My next job was to start working on the front lights wiring, I managed to get about half of it done as I have lost one of my front indicators which I had previously cut off ages ago and cant remember why or where I have put it!

I then decided to clean the garage floor as the car hasnt been moved since last November.

So the following pics show the car in daylight as it hasnt been out for a while! Also the last pic is the state of the garage floor!

Now its all been swept and the car put back inside until next weekend.

Title: Re: Phils 4thirty build
Post by: Paul79 on May 26, 2014, 10:30:24 PM
Very jealous of that lovely big garage you have there!!!  :)
Title: Re: Phils 4thirty build
Post by: cheets on May 26, 2014, 11:07:51 PM
Well i am just jealous of all the work you doing and there is me stuck at work looking good buddy  :)
Title: Re: Phils 4thirty build
Post by: Phils99 on May 27, 2014, 08:36:30 AM
Hey cheets! How u doing buddy?

My build has been on and off, same as yours, I actually bought mine before rudy and paul, and one is totally finished and the other one close!

Dont worry mate, you will soon be back on with it and hopefully loving the build as I am!

I love it so much, ive just been watching the Mark Evans "A Car Is Born" videos, and this is wetting my appetite to maybe, for my next build, build a car from the ground up as a fun powerful toy...and all for around £12k - £15k depending on the engine (the 5.7ltr engine in a car that weighs as much as a feather sounds interesting!)
...and yes, I have also watched all his other "is born" videos  as well!
Title: Re: Phils 4thirty build
Post by: MADMAN on May 27, 2014, 07:50:01 PM
Hey cheets! How u doing buddy?

My build has been on and off, same as yours, I actually bought mine before rudy and paul, and one is totally finished and the other one close!

Dont worry mate, you will soon be back on with it and hopefully loving the build as I am!

I love it so much, ive just been watching the Mark Evans "A Car Is Born" videos, and this is wetting my appetite to maybe, for my next build, build a car from the ground up as a fun powerful toy...and all for around £12k - £15k depending on the engine (the 5.7ltr engine in a car that weighs as much as a feather sounds interesting!)
...and yes, I have also watched all his other "is born" videos  as well!
             How about the helicopter is born? now that sounds interesting
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on May 27, 2014, 08:58:12 PM
Yea .....trying to find a download for that without much luck....
Title: Re: Phils 4thirty build
Post by: Hendrix on May 28, 2014, 12:29:25 AM

[/quote]
             How about the helicopter is born? now that sounds interesting
MADMAN 8)

[/quote]

That was an amazing series, in a way that has led me to this forum, was so inspired and ready to build something. DNA were the perfect start point
Title: Re: Phils 4thirty build
Post by: Phils99 on May 28, 2014, 08:25:21 AM
if only a kitcar company made a "doable" Gallardo kit ( come on DNA! This would be a MASSIVE seller!!)...I would be all over that one in a shot! (I Know a company down south does one, but, I havent seen or heard of a finished one as yet!)
Title: Re: Phils 4thirty build
Post by: Furrari on May 28, 2014, 09:38:24 AM
I watched the A ???? Is Born as well.  I watched it again after seeing the work of DNA.  I know it's a TV program and has to fit in time slot for each time slot and for the series but it's that some of the difficult jobs just appear as done rather than the just screw it together jobs.

I know we keep below the radar for good reasons but the build diaries on this site and the details are far, far better than any TV series.  It's inspirational.  I know I don't ( physically can't ) do much of the work but I am proud to be part of this club.
Title: Re: Phils 4thirty build
Post by: Phils99 on May 28, 2014, 10:49:47 AM
furrari,

yea, I thought that as well.....such as for example...."Im about to mount the front hub...see you after the break"..when it comes back on, all 4 hubs have been fitted and no more said!!

but it gave a great insight into building a car from scratch and it was mainly all nuts and bolts, something I am good at (I love doing "flatpack" furniture!!) as you dont have to fabricate anything as its all supplied with instructions or available from Pilgrim....

Lets see where my finances are when I finish my 4thirty, it maybe that I cant be bothered to build annother car and just want to enjoy my fezza...I doubt it though as it really is something to actually build a car yourself and then drive round in it knowing you created it!
Title: Re: Phils 4thirty build
Post by: cheets on May 29, 2014, 02:55:18 PM
Phil very busy just dun 9 city in 10 days got 4 more city to do bit tied lol

yes i do know what you mean got a lot dun before i left was hoping to get it ready for going to the pant shop next time i am back :)  just can not make my mind up on the colour keep looking on the net at different 430


I have see some of them but owes a way and wen back not got time for tv lol
Title: Re: Phils 4thirty build
Post by: Phils99 on May 31, 2014, 08:40:49 PM
Only gunna get 1/5 day on her this weekend, so today, I started with a "easy" job, but something that takes a bit of time, it was to add some rubber to my diffuser to stop it rubbing against the bodywork. This meany removing the 6 bolts holding it on and then having a look at it...

Pic 1 shows that the FG is too thick along the edge and it made the rubber edging not fit right

Pic 2, same on the other side, so I "thinned" them using the angle grinder

Pic 3, rubber fits nicely now!

Next onto the door cards...

Pic 4, looking acros the top of the drivers door, you can see that this part is too high for the door panel...

Pic 5 and pic 6, ...so I trimmed it down with the angle grinder

Pic 7, you also need to trim this bolt down as it stops the door card from touching the door

Pic 8, I also found that this raised part also restricted the door panel from touching the door, so I trimmed this down, it now fits lovely on the bottom part (apart from the slight twist in the FG panel, but that will be pulled straight when I fix the panel to the door)
Title: Re: Phils 4thirty build
Post by: Phils99 on May 31, 2014, 08:54:07 PM
Pic 1, Looking at the top of the door card near the wing mirror, it seemed to be pushed off the door by something, when I took the card off, I found the metal of the door was pushing the card out, so I trimmed it off as shown here.

Pic 2, I also had to trim the door card here to stop the window mechanism fouling the door card, the part of the card top left was already trimmed on my cards!

Pic 3, here is the top of the card from the outside of the car

Pic 4, I then cut out the hole that is marked for the door handle and test fitted it

Pic 5, Door arm rest fitted with front bolt and tape to line up the rear bolt

Pic 6, I then removed the arm and lined up the angle bracket I will be using to do the same as Paul and fit the door handle to the actual metal door so you are closing the door by pulling on the metal and not the FG

Pic 7, I then marked this area on the door panel and cut out a slot in the panel, I then inserted the bracket and fitted the door panel to the door (after removing the big plug...check Pauls build) to make sure that I can feel that the bracket is gunna bolt to the door in the correct place

Pic 8, I then removed the bracket, re fitted the door panel and scribed on the door through the slot in the door panel

Title: Re: Phils 4thirty build
Post by: Phils99 on May 31, 2014, 09:07:08 PM
Pic 1, bracket fitted to the door

Pic 2, door card all fitted!

Next job is to fit the "Ferrari" projector lights into the doors and I have also purchased a pair of real Ferrari redlights that I will fit in the end of the doors (When they arrive).  I will also fit my tweeters into the door panels and the door pockets as well....thats all for next time.
Title: Re: Phils 4thirty build
Post by: Phils99 on June 14, 2014, 07:36:15 PM
Had a day on her today, im telling you builders, if you decide to "spend a little time" on the door cards, be prepared for 2 days work!!!!

I started by getting the passenger door to the same fitted state as the drivers (see previous thread) This took a little more work as the pasenger one didnt seem to fit as nicely as the drivers and I had to add some spacers inside the top of the door card this made it a much more stable fit.

Next I decided to fit the speakers covers. I am looking to upgrade to the Focal 165a1 speakers which are a direct replacement for the OEM ones, so I trial fitted the covers for the OEM ones and this should be OK.

Pic 1, Cut out hole for the tweeters

Pic 2, after a little bit of shaping, the tweeter cover then fitted nicely!

Pic 3, When I fitted the original speaker back on the 430 door card, it has enough space between speaker and door card to fit the original speaker "mesh" inside, firstly it need to be removed by drilling out the plastic "rivets"!

Pic 4, I then cut out the mesh from the MR2 pocket moudling

Pic 5, I then just used gaffa tape to hold the mesh in place to test fit, when card has been upholstered, I will bond the mesh on from the rear

Pic 6, Drilled hole in the other door card, this is where the original tweeter fits behind the door card, I will get some sticky back foam strip and close the gap between speaker and door card

Pic 7, So onto the door pockets, time to steal Rudys and Pauls idea! firstly drill holes in the door card where the pocket will fit

Pic 8, Then take a bolt, washer and nut, tighten them up (as shown by the loose one in the middle) and drop it into the hole, you then use a washer and nut on the back to secure it for now.

Continued.......

Title: Re: Phils 4thirty build
Post by: Phils99 on June 14, 2014, 08:03:16 PM
I then, at the end of the day lifted off the door pockets, sanded the back of the pocket for the sikaflex to have a grip, I then coated the top of the bolts with a load of sikflex, placed the door poacket on top and will leave to dry.

Pic 1, door pocket laid on the bolt heads nicely in the correct position

So onto more door work, firstly, I manged to buy a pair of second hand original Ferrari red door lights, so I drilled a hole in the end of the door and inserted the light, I have held it on with some tape, as, if I fit the screw, as these lights are secondhand, the rubber has shaped slightly, so each light needs to be fitted and left fitted, as, if I create the securing screw holes now, I bet when its back from paint, I cant get the light to line up exactly, so I will fit the securing screws when its back from paint

Pic 2, light taped in place

Pic 3, add a battery!! I will wire these up when it comes back from paint as I need to connect these to the door switches.

Pic 4, So next was a "Ferrari" projector light, this simply fits in the bottom of the toyota door, again, I will wire these up when back from paint.

Pic 5, Last job on the door, I purchased a couple of vauxhall door locks which need fitting

Pic 6, All these holes I have drilled with one of these a stepper drill bit, these are amazing and so simple to keep slightly enlarging until it fits!

Pic 7, and there we are, the hole drilled and the lock just held in place with my hand for now, I will create a mount for this next time
Title: Re: Phils 4thirty build
Post by: Paul79 on June 15, 2014, 08:09:35 AM
Looking great Phil. Love all the little extra touches with the lights etc...yes the door cards take ages but will be worth it in the end. You thought about the interior time colour you are going for?
Title: Re: Phils 4thirty build
Post by: ghall164 on June 15, 2014, 09:46:58 AM
 ;) lovely work phill she's coming along nicely  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on June 15, 2014, 10:21:04 AM
cheers guys....

Paul, my interior colour will be cream, same as Madmans
Title: Re: Phils 4thirty build
Post by: Phils99 on July 12, 2014, 10:19:17 PM
got half a day on her today, so I carried out lots of little jobs, firstly I looked at the mirrors and cut the hole in the door part for the mirror adjuster cable, no pics  of this, but then I decided to trim the rubber seal on the door near the mirror...

Pic 1, this is the piece that needs trimming

Pic 2, After the rubber is trimmed, it has this metal part inside it...

Pic 3, I used the grinder to remove the metal part, it now fits nicely

Pic 4, I then did a little sanding of the front door gaps as, after securing the wings to the light carriers, they were just catching very slightly.....

Pic 5, next it ws onto the bonnet stops, I first marked the centre of the flat "square" part

Pic 6, I then checked the size of the supplied bonnet stops and marked it on my stepped drill bit with insulation tape

Pic 7, I then drilled the hole, stopping before the insulation test and trial fitting the stop, and just doing it little by little until it nearly fit, I then used a tiny round file to create the "notch" that stops the lower part of the stop spinning when adjusting it

Pic 8, Lower part of stop fitted...

continued....


Title: Re: Phils 4thirty build
Post by: Phils99 on July 12, 2014, 10:26:43 PM
...continued

Pic 1, upper part of stop fitted

Pic 2, I then looked at the front scuttle and cut this piece out of some spare I had cut off the wheel liners to match the shape of the scuttle part

Pic 3, I then bonded this with P40 on the rear

Pic 4, when dried, it now looks like this from the front

Pic 5, test fit...it fills the gap nicely, just needs a little sanding, some P38 filler and then painting with the textured paint,. I will save that job for when the car is at body shop.

Thats it for now, plan a full day on her tomorrow so hopefully many more little jobs will get done.

Title: Re: Phils 4thirty build
Post by: Phils99 on July 13, 2014, 05:02:54 PM
yet another day on the car!!

again, managed to work on lots of little things such as drilling drain holes in the rear bumper to stop water collecting...

Lots of other bits and bobs done and some took a good few hours, like messing with the frunk surround to get the water bottle filler to fit, this is a mark up/take off/cut/refit type of job so can take a while to get it to fit nicely, but its worth it.

Pic 1, For the washer bottle to fit better, remove this now useless bracket

Pic 2, I then cut the neck as the washer bottle needs to be in a different position, I will buy some flexi pipe and jubilee clips to fasten them back together later

Pic 3, I decided I really needed the front bumper off to fit the washer bottle, but couldnt be bothered to take it off today, so I will fit the washer bottle another day. instead I marked the frunk cover where I need to remove some of the plastic so that the filler cap will fit.

Pic 4, I then removed this piece, refitted, marked again, removed, cut the piece out, refitted etc about 3 times until it fit nicely (thought I had a pic of it finished.....but I havent!)

Pic 5, as my car originally didnt have the alarm system fitted, I also had to cut out the slot in the frunk cover for the plunger. This again was trial and error, and also made it imposible to get the cover on with the plunger fitted, so I moved the bolt and drilled another hole in the plunger bracket to get it to nearly the right height for the bonnet. I fitted it and then connected 2 wires to it to test if the bonnet pressed it down, closed the bonnet and it worked a treat, you just have to remove the plunger and bracket if you are removing the frunk cover...which wont be often!

Pic 6, after the doors are fitted, you end up with a gap here, so I mixed up some P40 and filled in the gap, the body shop will do the final filling of this during prep...

Pic 7, here is the gap filled, I did this on both sides...

Pic 8, last job of the day I fitted the wiper based washers and trial fitted the washer pipes, hooked up the washer bottle and gave it a quick test, all working nicely!


Title: Re: Phils 4thirty build
Post by: Paul79 on July 13, 2014, 08:27:32 PM
well done matey. getting closer and closer.. that must have ticked a few jobs off the to do list....  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on July 21, 2014, 08:17:17 PM
Had a day in garage on sunday, but the garage was a mess so spent an hour or so tidying up!

So next, I decided to do the wiring for the headlight and main beam.....

Now mine is a prefacelift and I have 3 wires, doesnt matter about the colours lets call them 1, 2 and 3.

When I turn headlights on, I get a battery on 1 and an earth on 2 and nothing on 3...so thats obvious then, connect the headlight to 1 and 2, done...

Now when I flick the main beam on, the earth on 2 goes OFF and I get an earth on 3, so connect the main beam gate to 1 and 3, done

Ok, so now I have a problem....on low beam, headlight on, gate closed, on high beam headlight off, gate open!
it worked originally on the mr2 with a dual filament bulb and it either lit one side or the other for low/high beam...

How can I get this to work with 1 bulb and a gate?

 If I connect the earths together, then the bulb is constantly on, and the main beam gate is constantly open!

Help!!
Title: Re: Phils 4thirty build
Post by: tenpin on July 21, 2014, 10:14:02 PM
My quick thoughts - you'll need a changeover relay.
Connect the gate between 1 and 3.
Connect the relay coil between 1 and 3
Connect the bulb to 1 and the other end of the bulb to the changeover relay contact (common)
Connect the relay normally open (NO) to 3
Connect the relay normally closed (NC) to 2

Have a think about that and hopefully it will make sense, also hopefully I've got it right.... been up far too many hours to think straight.....

 - tenpin
Title: Re: Phils 4thirty build
Post by: Phils99 on July 21, 2014, 10:18:53 PM
Cheers tenpin, but is that what everyone had to do with a prefacelift?

I havent seen any write ups mention relays for the headlights.....

Anyone actually wired up prefacelift headlights?
Title: Re: Phils 4thirty build
Post by: Paul79 on July 21, 2014, 10:52:39 PM
Hi Phil, sorry you're having issues with your lights. Beany's car was a pre face lift. Post face lift was simple. A connector plug with 2 wires for headlight and a connector plug with 2 wires for the main beam. On the pre FL was there a shared connector?
Title: Re: Phils 4thirty build
Post by: CdRsKuLL on July 21, 2014, 11:48:48 PM
Hi fella, I had something similar on my Mk2 MR2.  All the lights are earth switched, which means they always have a positive feed (single wire) and two switched earths for the main and dipped bulb.  I got round it by inserting a diode I think (was a couple of years ago.. lol )


I've attached a quick diagram showing you what I mean. This will turn both bulbs ON when the main beam is selected but only the dip beam when that's selected. Is that what you're after?

NOTE - please remember if powering two bulbs that the current will increase and the wires might not carry that type of juice.. nor the fuse, if you're using xenon kits then this uses a separate power unit and only uses the feed to operate the magic box which is what I used.

thanks

Steve
Title: Re: Phils 4thirty build
Post by: Phils99 on July 22, 2014, 08:34:04 AM
cheers Steve, that is similar to my issue, but in the Hella headlights we only have 1 bulb, we need to keep this on when we engage main beam which isnt a bulb, but a metal "gate" that drops allowing more light from the bulb.

Your diagram will work if I connect the main beam gate where you have the main beam bulb, its another solution I can try
Title: Re: Phils 4thirty build
Post by: DNA AUTOMOTIVE on July 22, 2014, 10:18:16 AM
Hi,
According to boys at DNA, which is where I am at the moment:

Driver Side:
Red/Blue - take to both lamp and Gate
Red/Yellow - take to gate
Red/Green - take to lamp

Passenger side:
Red - take to both lamp and gate
Red/Green - take to lamp
Red/Yellow - take to gate

Hope this helps,
 - tenpin
Title: Re: Phils 4thirty build
Post by: Phils99 on July 22, 2014, 10:54:44 AM
Tenpin,

unfortunately, im away at the moment in London so I cant check, but I dont see how this would work, as, cdrskull confirmed, these use a switched earth system as they are lighting up one side of the original MR2 bulb or the other with the common being the battery, if I do as you said in previous post, I can turn on the bulb OR open the gate, but not both at the same time (for high beam)!

Im pretty sure the only way will be with a relay or a diode.

Title: Re: Phils 4thirty build
Post by: Phils99 on July 22, 2014, 02:02:59 PM
ok guys, after much research and many emails from people (thanks guys) this will be the way to do it as seen in this thread from MR2ROC to convert from prefacelift (1 bulb with 2 filaments) to facelift (2 bulbs, 1 dip, 1 main - which will be similar to Hella 1 bulb, 1 gate).

http://www.mr2roc.org/phpBB3/viewtopic.php?f=31&t=30838&hilit=+facelift+headlights (http://www.mr2roc.org/phpBB3/viewtopic.php?f=31&t=30838&hilit=+facelift+headlights)

NB. REPLACE THE "MAIN" BULB IN THE DIAGRAM WITH THE "GATE" FOR THE HELLA HEADLIGHT

It is done with a relay so that the earth that switches from one wire to the other when main beam applied gets switched via the relay to keep the bulb on AND operate the gate.

I will try this at the weekend to confirm but I am sure this will work.

I am totally suprised that this hasnt been a problem for other builders? if it does work, I will create a "how to" for it.
Title: Re: Phils 4thirty build
Post by: Phils99 on July 22, 2014, 02:19:37 PM
updated diagram...

Title: Re: Phils 4thirty build
Post by: Paul79 on July 22, 2014, 05:00:31 PM
Good work Phil and I hope it works out for you. I think it is just most builders have used post facelift model MR2 models so we wouldn't have faced these issues before...
Title: Re: Phils 4thirty build
Post by: tenpin on July 22, 2014, 10:53:12 PM
How about:
Take 1 to bulb and gate
Take 3 to gate
Run a new permanent earth to the bulb

So, headlight switch off, no 12V on 1, so nothing happens.
Turn headlights on, 1 goes to 12V  and bulb lights all the time, doesn't matter which position Main/Dip switch is in.
Move switch to Main beam and 3 goes to earth, hence gate activates.
2 is totally ignored.

Your thoughts on this?

 - tenpin
Title: Re: Phils 4thirty build
Post by: Phils99 on July 23, 2014, 09:00:57 AM
that is another idea and one that could work!, I will have to check if the 12v to the bulb is there all the time or switched when the earth is switched...I can try this method easily next time I get a chance.....
Title: Re: Phils 4thirty build
Post by: Lord Beany on July 23, 2014, 09:54:26 AM
I'll see if i can find my wiring sketch for the headlights. My car is a 2002, I wired them as Roland instructed me and there were no issues at all.

Will post again later.

Beany  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on July 25, 2014, 09:12:06 PM
Right, so I rushed home from work (London to Hull on the train!) sorted out my washing and eagerly went into the garage to sort out the headlight wiring......

I have 3 solutions on the plate (see previous posts):

1. DNA's solution of using the 3 wires as they are,
2. Tenpins solution to add a perm earth
3. MR2ROC solution of using a relay

I knew it wouldnt work, but I tried the DNA solution first and this DOESN'T work on my car due to the "switched" earth, i.e. you can either have the light on or the gate open, but not both at the same time....

So I moved onto Tenpins simple solution, which is to run a permanent earth to the lamp (as turning the lights on puts a battery onto the other wire) and wiring the gate across the same battery and the other switched earth wire....IT WORKS!!

This works perfectly and just leaves one wire unused.

I then soldered all this up, added the heat shrinks and taped up all the wires.
I then refitted all front lights, indicator, side and head and tested them, all working perfectly.

I then "bagged" all the wiring up to protect from dust and paint when it goes to the body shop.

So, for all you prefacelift builders (if any out there, you all seemed to be building on facelift cars) here is the wiring to use:

Drivers side

Red/Blue - take to both lamp and gate (+12v)
Red/Yellow - take to other side of gate (switched Earth)
Red/green - NOT USED (was the switched Earth to the lamp)
Earth - take a new Earth from the body to the other side of the lamp

Passenger side

Red - take to both lamp and gate (+12v)
Red/Yellow - take to other side of gate (switched Earth)
Red/green - NOT USED (was the switched Earth to the lamp)
Earth - take a new Earth from the body to the other side of the lamp

This works as follows:
When headlights are switched on, the car switches a 12v and earth feed to 2 of the wires, when high beam is engaged, the earth switches from the first earth wire to the second. In this solution, we add a permanent earth to the lamp, that way, when the car switches the first earth off, we keep it on the lamp with the new earth we have added and the gate is opened to give high beam with the lamp still on.

Again, special thanks to Tenpin for his great solution.
Title: Re: Phils 4thirty build
Post by: Paul79 on July 25, 2014, 11:32:47 PM
Good work Phil, and shouts of "Strike!" to Tenpin...................................

..............(tumble weed across the screen).............

Sorry guys! I'll get my coat!  ;)
Title: Re: Phils 4thirty build
Post by: Phils99 on July 26, 2014, 09:20:25 AM
lol..nice one Paul!
Title: Re: Phils 4thirty build
Post by: Lord Beany on July 26, 2014, 10:24:32 AM
Just found my wiring scribbles and have pretty much the same as you have done it, although on the driver side i have a blue/green cable that i capped off not red/green. My car is UK spec, not sure about yours?

I also used the connectors from the old side repeaters to connect the two wires to the switch cables on the rear of the lights.

I'm pretty sure Roland gave me these instructions.

Glad you got sorted mate.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on July 26, 2014, 07:16:18 PM
Cheers Beany, thanks for the info.

Had a few hours today,

Pic 1, so firstly, I realised that I couldnt get the lid off the fusebox next to the battery very easily, so I took a lump out of the fibreglass to make it easier. now it comes off with not too much trouble

Pic 2, I then started work on fitting the OEM centre console I have bought, I needed to move the hand brake, this pic shows the original position of the MR2 handbrake in the middle and forward...

Pic 3, This shows where I had to move the handbrake to to fit the console, further back and nearer the driver

Pic 4, I had to trim a little off one of the mountimg points of the handbrake otherwise it would stick out

Pic 5, this shows where it would have stuck out if 'i hadnt trimmed it

Pic 6, cable reconnected, I had to shorten the cable by adding a few components on the left hand end and its at a slight angle but it still works fine

Pic 7 and 8, I then laid on the OEM centre console to check the handbrake fits and works and it works great!

I will get a good day on it tomorrow and hope to get the centre console further on, may even start some more interior work!

2 weeks until body shop!!
Title: Re: Phils 4thirty build
Post by: Paul79 on July 26, 2014, 09:25:12 PM
Nice work on the centre console. On the last picture I am loving the bucket seat. Lol. :)
Title: Re: Phils 4thirty build
Post by: rudycob1 on July 27, 2014, 01:53:12 PM
Looking good mate, soon it will be transformed by colour :)
Title: Re: Phils 4thirty build
Post by: Phils99 on July 28, 2014, 10:19:23 AM
not much to report and no pics....


I spend THE WHOLE DAY cutting and shaping the existing MR2 centre console to take the Ferrari OEM one and I am nearly there....

I just need to move the handbrake lever a few mm nearer the driver as its pushing the console off centre.

I also dug out the interior kit as I was going to cut out all of the holes for the air vents.

I opened my "cheapo" hole cutting kit and found I have a 76mm and a 85mm hole cutter...but no 80mm one, which is what the holes are.....bummer.

I have ordered a "adjustable" hole cutter now off ebay so should be able to do these next week.

I cut out the area where the main heater controls will be and cleaned that up a little...then, before I knew it, it was the end of the day!

It seems that I didnt get much done for the whole day really, some of these jobs just eat all of the time!

One more weekend with the car and thats it...off to body shop!
Title: Re: Phils 4thirty build
Post by: ghall164 on July 31, 2014, 09:29:10 AM
 :D great job on the console Phil she's going to look great ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on July 31, 2014, 12:10:37 PM
thanks ghall!
Title: Re: Phils 4thirty build
Post by: beemaman on July 31, 2014, 02:04:37 PM
Bodyshop soon mate bet you can't wait :) great work buddy keep it up
Title: Re: Phils 4thirty build
Post by: Phils99 on August 03, 2014, 08:36:56 PM
Last day of work on the car before it goes to paint.

Firstly I had to get the trailer ready for next week, this meant I had to grind off the two sides that were making the trailer to narrow for the car and then I attached my number plate.

Pic 1, sides trimmed to allow the wide car on

Pic 2, trailer hooked up, I also tried that car on to see if it fit and it does...so far so good!

Pic 3, 4, and 5, back to the centre console, Beemaman mentioned that the OEM Ferrari console may interfere with the seats, so I put the seats back in to make sure the console fit and it fits fantastic!

Pic 6, this is the part I had to cut off from the MR2 console

Pic 7, and  then it fits on top like this

Pic 8, This left a big hole at the end of the console so I used a piece of offcut plastic from the wheel arch liners to cover it



Title: Re: Phils 4thirty build
Post by: ghall164 on August 03, 2014, 08:40:22 PM
Lovely neat job there Phil nice touch :)
Title: Re: Phils 4thirty build
Post by: Phils99 on August 03, 2014, 08:46:07 PM
Pic 1, So I Plastic welded this piece on with a soldering iron and I then used P40 to bond it on from the back

Pic 2, I then started on the gear lever, this sits high, just like a real Ferrari one does, but I needed to shroud it, so I cut the piece of the MR2 console and after hours of removing a little, retrying and removing some more etc, I eventually got it to fit right.

Pic 3, I then used tiewraps to hold it in place and using P40 again, bonded this part on. This will end up being covered with leather when I get the console done by the uoholsterer.

Pic 4, from the top...

Well, thats it then...off to painters next week!
Title: Re: Phils 4thirty build
Post by: Phils99 on August 08, 2014, 09:59:13 PM
Checked the car over for the last time and removed anything not needed by the paint shop...

Here is hopefully the last picture of this car in this state in my garage!

The rain has been coming down in buckets all night, hopefully its gunna be a nice day tomorrow...before the big storm hits on Sunday! by the weather forcast I think I may be lucky tomorrow...
Title: Re: Phils 4thirty build
Post by: MADMAN on August 08, 2014, 10:42:21 PM
Looking good Phil, wheel spacers checked 93 times?
Soon be back with that special green machine paint ;) ;)
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Paul79 on August 08, 2014, 11:27:17 PM
Good luck mate. I know it will be a bit stressful and emotional but it's all part of the journey. I hope it all goes well for you. Send my love to the DNA boys.
Title: Re: Phils 4thirty build
Post by: rudycob1 on August 09, 2014, 08:15:17 AM
Another milestone day in the history of the build.
Well done mate and enjoy.
Title: Re: Phils 4thirty build
Post by: ferrari feb 14 on August 09, 2014, 08:56:39 AM
Hey phill looking good all your hard work has paid off , bet you can't wait to see her with some colour on ,hope to see you at donny if you are down cheers jd
Title: Re: Phils 4thirty build
Post by: Wizard on August 09, 2014, 10:12:39 AM
Phil. It will look fantastic in white  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on August 09, 2014, 03:16:34 PM
Well I can report...............ALL WENT WELL!!

I managed to get to DNA with NO INCIDENTS and all FOUR wheels on the car!!

Brian cast his masterful eye over the car and obviously spotted some things that need doing, thats fine, I had no illusions about that, of all parts of the build, the main bodywork bonding was the least enjoyable bit for me, anyway, its with the experts now and we have agreed its going to be that little bit special when it is done, I wont say how or why, you will have to wait for the finished product.

Madman - all wheel spacers thread locked now...we learn by our mistakes!!

Pauls79 - it was very stressful, I had visions of the car falling off the trailer whilst doing 55 MPH!...it looked mean in the rear view mirror though, as if you have a monster car tailgating you :-)

Rudycob - cheers mate, soon be able to join the "club" for real instead of a "wannabe"!! :-)

JD - cheers mate, Im defo at Donny, you better have yours ready by then!

Wizard - If I went white, the number of whites would be taking over the reds!! :-)


Anyway, some pics for those who like them (thats all of us!!)

Pic 1 and 2 - all loaded on the trailer and ready to go...I had to do all this on my own...I was a bit worried that I wouldnt get it on right, but it went on OK first attempt!!

Pic 3 - so you know im not telling porkies, here is my car sat outside DNA's unit

Pic 4 - and car now off trailer and in the yard waiting to be worked on, I took this to also show the front and rear clips of the West Coast!

Pic 5 - and finally, a pic of Furraris West Coast build, I have to say, these car look absolutely awesome when you see them for real!, should have brought a can of Rosso red to give it a spray :-)
Title: Re: Phils 4thirty build
Post by: Lord Beany on August 09, 2014, 04:56:09 PM
Well done mate. I remember loading mine on the trailer for the same jouney, using planks under the rear wheels to avoid scraping the sills. Lol. i actually had a close call in DNAs' yard when i attempted to drive away from the trailer with the safety cable still attached ::) Brian nearly shat himself. Lol.

I hope Furrari gave permission for the shot of Furrari II.  :-X

It looks really good though.

Looking forward to see what the special look is.

Beany ;D
Title: Re: Phils 4thirty build
Post by: Furrari on August 09, 2014, 07:26:57 PM
Phill/Beany.

No probs with pictures of the Furrari ( other than it's better than the one I took)

The only problem is with the "R" word.

All Furraris are YELLOW.

The West Coast is impressive isn't it.  The SL is big but the West Coast is a couple of inches a side wider at the back.

The West Coast won't need planks cos you can adjust the ride height at the press of a button.

Looking good mate.  See you at Donnington
Title: Re: Phils 4thirty build
Post by: Paul79 on August 09, 2014, 08:28:04 PM
What is great is if you actually look at the west coast, it is smiling. Not as much as Mick but it definitely is a happy bunny.   ;D
Title: Re: Phils 4thirty build
Post by: seriph on August 09, 2014, 10:18:26 PM
And just think mate: soon you'll be able to share your build story with all its wins and challenges, while ppl admire your chariot.

Although I'm not in 'the club' I do know how great it is to be able to say " look at what I built" - it's far better than only being able to say "hey look at what I bought"

Well done sir
Title: Re: Phils 4thirty build
Post by: Phils99 on August 18, 2014, 07:52:31 PM
Ok guys DNA have been on and told me they managed to straighten up the front clip which was the main issue...cheers Brian, you see, they wont just slap paint on whatever you drop off, they want EVERY DNA car to be perfect!...im happy with that approach! They sent me some picks of the body now perfectly aligned....just look at those lines!!!
Title: Re: Phils 4thirty build
Post by: Wizard on August 18, 2014, 08:08:37 PM
Fantastic attention to detail. That what makes these cars so great.

Bet you can't wait to get this painted in white, oops sorry I meant RED.  ::)
Title: Re: Phils 4thirty build
Post by: Paul79 on August 18, 2014, 10:54:55 PM
Lovely gap work there. Roll on paint colour #322.  ;D
Title: Re: Phils 4thirty build
Post by: tenpin on August 18, 2014, 11:20:16 PM
Lovely gap work there. Roll on paint colour #322.  ;D
I thought they sprayed it on, maybe with 322 it's done with a roller  ;D , but then what would I know - it's the wrong end of the colour spectrum for me  ::)

 - tenpin
Title: Re: Phils 4thirty build
Post by: Paul79 on August 18, 2014, 11:25:15 PM
Lovely gap work there. Roll on paint colour #322.  ;D
I thought they sprayed it on, maybe with 322 it's done with a roller  ;D , but then what would I know - it's the wrong end of the colour spectrum for me  ::)

 - tenpin

Haha. I didn't see that little joke I put in there. Bit late for me. Brush instead? My girls would love to do that!
Title: Re: Phils 4thirty build
Post by: Phils99 on August 19, 2014, 08:29:35 AM
heheheh..you guys!!

makes me laugh all the banter about the colour the car should be painted, ive seen it many times on here as other guys cars have gone to paint shop...but now its about MY CAR! its a great feeling!

keep the banter going.....and see you all very soon at Donington!, although as I said earlier, the green machine is out of action at the moment....
Title: Re: Phils 4thirty build
Post by: MADMAN on August 19, 2014, 09:00:44 AM
A up M8,
             What,s the problem with the Famous green machine? I read it,s to do with a track day, but not the details. Mechanical or crumple? Can it be brought back to life?

MADMAN
Title: Re: Phils 4thirty build
Post by: Phils99 on August 19, 2014, 09:48:54 AM
I was driving it round the track and it just shutdown on me.....didnt seem or sound mechanical and now it just wont start.

I have turned it over and checked the OBDII socket, but no errors are shown. AA man who tried to get it going says it has fuel, spark and air but he cant understand why it wont start...and neither can I :-( not sure what to do next really....I might see if I can get some time on it this weekend....I miss it!
Title: Re: Phils 4thirty build
Post by: johnjames on August 19, 2014, 12:10:04 PM
Hi Phils did the green machine see the new 430 car it could be jealous you know cars are like females they need lots of attention hope to see you in the green machine at Donington take care J J
Title: Re: Phils 4thirty build
Post by: rudycob1 on August 19, 2014, 06:48:29 PM
Phil, sounds electrical or electronic if everything else seems ok.
Hope you get it sorted mate.
Title: Re: Phils 4thirty build
Post by: DNA AUTOMOTIVE on August 19, 2014, 07:23:50 PM
check the main 30amp fuse large one at the back f the fuse box in the rear of the car
Title: Re: Phils 4thirty build
Post by: Phils99 on August 19, 2014, 08:09:19 PM
Good idea! I will check that fuse when I ge4 home on friday....I will fall about laughing if it is that :-))
Title: Re: Phils 4thirty build
Post by: Phils99 on August 24, 2014, 09:19:40 PM
green machine...all fuses checked and OK :-( car still not working...anyway, back to the build thread!

I had a go at the fake engine today, having talked to a couple of owners, they state that heat from the engine can be felt in the car when stood still, so, like others have done I decided to cut out areas of the fake engine to increase heat dissipation through the engine vents in the rear deck.

Pic 1, foim the top of the fake engine I drilled holes in the "corners" of where I wanted to cut out

Pic 2, I then cut them out very easily with this!

Pic 3, roughly cut out ready for the detailed filing and sanding

Pic 4, after sanding....

Pic 5, I then did the other side and removed some of the base from the middle of the fake engine

Pic6, I also noticed that the sides kind of sealed the fake engine against the rear deck ,so the heat woiuld get trapped inside the fake engine under the glass, so I decided to remove the sides. I will replace the sides with mesh and also mesh over all the other cut outs as well after painting.

New builders: This part is very time consuming and took me all day to cut these out and cut out the mesh...but it was enjoyable!

I have ordered the jubille clips and allen bolts ready for next time I work on it.
Title: Re: Phils 4thirty build
Post by: Phils99 on August 25, 2014, 07:06:51 PM
so today, I decided to have a go at the scuttle and the interior air vents.

Pic 1, here is the scuttle extension I had previously bonded into place

Pic 2, I then applied some P38 filler to fill the gap

Pic 3, after filler had dried, I then sanded down to make it smooth, this nearly ready to apply the "textured" bumper paint I have, I will do this later as I still need to reattach the central air intake.

Pic 4, next I started on one of the single vents, first stage is to cut out the large circle

Pic 5, I then kept enlarging it with sanding and filing until the vent fitted

Pic 6, the vent wont really fit from the rear correctly and its also stopped by these lugs...

Pic 7, So I removed the lugs.....and it fits nicely now!

Title: Re: Phils 4thirty build
Post by: Phils99 on August 25, 2014, 07:17:59 PM
Pic 1 and 2, next step is to remove the "elbow" from the vent connecting pipe

Pic 3, here it is fully assembled.

Pic 4, Now I started on the central 2 way vent and cut out the centres

Pic 5, due to these being very close, they dont all fit together, so I had to modify the outer ring of the middle one so that it would fit inbetween the other two

Pic 6,...and here we have all 3 fitted together!

Pic 7, so I placed them in the dashboard to see what they look like..Im very pleased

Pic 8, I then set about prepping and sanding all the bezels and the interior vent kit, this is going to need a little filler just to tidy a couple of spots up, but not much and they will soon be ready for painting.

until next time (at least 2 weeks as its Donington next weekend! see you all there!)




Title: Re: Phils 4thirty build
Post by: rudycob1 on August 25, 2014, 07:35:13 PM
Looking good mate.
Title: Re: Phils 4thirty build
Post by: Phils99 on September 07, 2014, 10:28:15 PM
another day today prepping parts for painting...

I started with more work on the fake engine.

Pic 1, I needed 6 hose clips and I found Halfords do this pack of 10 for under £6 these should do the job!

Pic 2, I cut the hose clip here and then drilled out a slot either side and then slotted it through

Pic 3, it looks like this from underneath, I will bend the ends over when I fit them after paintiing

Pic 4 and 5, had to carve out some of the fibre glass to get the hose clip to fit correctly

Pic 6, here are the 3 hose clips fitted

Pic 7, here the underneath with all 6 fitted!

Pic 8, I then drilled holes and fit all the bolts, here is a pic with the bolts and hoseclips fitted...just need to get the MAF sensors now....
Title: Re: Phils 4thirty build
Post by: Furrari on September 07, 2014, 10:32:27 PM
Phill.  I always said it was a replica engine but genuin jubilee clips.
Title: Re: Phils 4thirty build
Post by: Phils99 on September 07, 2014, 10:37:11 PM
Now, I really didnt like the way the interior centre airvent moulding just lays on top of the heater controls virtually obstructing some parts of the heater controls, so I decided to see if I could actually move the heater controls forward a little from the dashboard and fit the front of the heater control panel flush with the center air vent moulding, similar to the real 430.

This tooks hours of work just removing a little of the panel front and retrying to see if it fits

Pic 1, in the end, I managed to get a rough fit inside the centre vent moulding

Pic 2, from the side, as you can see its flush with the front

Pic 3, starting to bond the heater pamel to the surround, I will do this in a few stages so I can get it to sit flush

Its looking good at the moment, need more bonding and filler but it will defo work! well pleased.
Title: Re: Phils 4thirty build
Post by: beemaman on September 07, 2014, 10:44:07 PM
Good work phil

I like the fascia vent and blending it in to the control panel.wished I'd had done that :)

When's your car back buddy ? Bet your froffing at the mouth to get it back :) more than you was at wedding looking at those ladies :)
Title: Re: Phils 4thirty build
Post by: Phils99 on September 07, 2014, 11:21:37 PM
lol! yea...can't wait to get it back...but I'm so behind getting all the bits prepped for when it returns...I have had lots of busy weekends and I have another lads weekend in bruges next weekend, but after that, the next two weekends will be dedicated to spraying up the parts ready for the return...
Title: Re: Phils 4thirty build
Post by: ferrari feb 14 on September 08, 2014, 12:33:30 PM
Looking gud phill some great work ,it really makes a difference when you  use things like real dubilee clips, bet you can't wait to get her back from paint ,I no I'm like a kid at Christmas at the minute fitting mine up , jd
Title: Re: Phils 4thirty build
Post by: Phils99 on September 15, 2014, 03:38:25 PM
not much to report as I havent hardly had any time on her over the last 3 weekends!

I managed to get an hour purely because I wanted to finish the P40 bonding of the hvac control panel flush with the interior kit centre air vent moulding so that next weekend I can move forward in getting it prepped for paint.

This I have now done, its going to need some filling and sanding to smooth it all out but its looking good!

I also had to do a small repair to the fake engine, as, when I drilled out one of the bolt holes, it cracked all the way around, fortunately, I managed to rescue the broken part and bonded it back on and now its fine!

So I am looking forward to the weekend as I will have half a day on Saturday and a full day on Sunday....I may get some painting done if I finish all the prep work!
Title: Re: Phils 4thirty build
Post by: MADMAN on September 15, 2014, 11:03:36 PM
Great idea the HVAC panel moving flush,
 may be another winter project on mine, thats after I,ve got the dipping kit and had a play with it  ;D
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on September 16, 2014, 08:22:35 AM
yea, im hoping it will look just that little bit more OEM, hurry up and get your dipping going, Ive got loads for you to do already  ;D ;D
Title: Re: Phils 4thirty build
Post by: rudycob1 on September 16, 2014, 10:05:39 AM
Madman,
I'm sure I can give you a few things to dip as well  :)
Title: Re: Phils 4thirty build
Post by: MADMAN on September 16, 2014, 09:38:33 PM
Probably a few weeks before I get time to start this project, but it,s in hand
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: MADMAN on September 17, 2014, 12:46:27 PM
Probably a few weeks before I get time to start this project, but it,s in hand
MADMAN 8)
           got a dipping tank today ;D
Title: Re: Phils 4thirty build
Post by: rudycob1 on September 17, 2014, 01:18:26 PM
Best start getting some material samples now  :)
Title: Re: Phils 4thirty build
Post by: Phils99 on September 20, 2014, 09:22:16 PM
Ok, so this weekend was to fully work on my car...until some work cropped up for today and on-call tomorrow :-(

Anyway, I managed to get a couple of hours in the garage...

To start with, I never got round to bigging up Madman on welding my seats for me!! Cheers Steve!

Pic 1, the standard pre facelift MR2 seat is shaped like this and needs to have a square part at the top to look like the Ferrari headrest

Pic 2,  after cutting and welding, the sponge is removed and a squarer head rest is welded on

Pic 3, this needs a "shoulder" part with an added bit of box section

Pin 4 and 5, I have now found 2 vauxhall MAF sensors and have cut them out and bonded them onto the fake engine, the bungee is just to keep them in place while the bond goes off

Pic 6, Back onto hvac controls, I have now sanded and filled the unit

Pic 7, I then decided to primer it so that it will show up the areas that need more filler, and the fact that I was desperate to spray something!!!! its coming on and I think its gunna look great, its taken a lot of time to get it to this stage....

Pic 8, I also primered the outer air vents

I hopefully will get a good day tomorrow if I dont get called up....

Title: Re: Phils 4thirty build
Post by: Lord Beany on September 21, 2014, 10:14:49 AM
Vents are looking great Phil, brilliant idea.

Presumably there was enough play in the controls behind and the original fixings are used behind the dials?

Beany  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on September 21, 2014, 05:36:18 PM
cheers Beany...yea, enough play to move the hvac unit forward and all original fixings for the front will be used.
Title: Re: Phils 4thirty build
Post by: Phils99 on September 22, 2014, 05:22:42 PM
So, my intentions for Sunday was to firstly fit my new tow-bar to my newly acquired BMW 5 series so that I am ready to tow the trailer when I get the call from DNA and also do some more work on my car bits...

Fitting the tow-bar itself is pretty straight forward, bumper off , unbolt metal bumper, bolt on tow bar, refit bumper, sort wiring, but, I didn't allow for:

A) neighbours son who is moving out coming over and asking me to help him lift his big TV and other stuff into his car....loss of 1 hour of my car time!
B) a stranger coming on my drive and asking "is the house for sale?", which it is, and then, so as not to miss a potential sale, me showing them round my VERY untidy house, apologising for every room ( I am having a cleaner from next week!)...loss of 2 hours
C) neighbour appearing again asking for more help....loss of another hour.....

All in all, after trying to decipher the wiring instruction and then fitting it all back together, I didn't finish the tow-bar until 4pm!

At this point, it had been a long day, but I went in the garage and pottered around for a couple of hours anyway.

No pics, but all I managed to do was some slight adjustments to the door card pocket fixings, making the holes bigger so that it can be more easily fitted and removed, and a little bit more filling and sanding of the centre air vent

I intend to have a good one and a half days on it next week...im nothing "pops" up (I think I may close the garage door and lock myself in!)...I need to get painting!
Title: Re: Phils 4thirty build
Post by: Phils99 on September 28, 2014, 08:59:19 PM
...so had a good weekend in the garage and managed to get a lot of stuff done....all painting jobs!!

Pic 1, 2 and 3 my painting production line showing the front scoops, rear exhaust surround and the side air intakes all primed.

Pic 4, I also decided to paint the wipers as they were starting to look a little worn and would bring the look of the car down

Pic 5, fake engine all primed

Pic 6, I then noticed that the "r" had lost a portion at the bottom

Pic 7, I bit of filler later and its now good enough....

continued....
Title: Re: Phils 4thirty build
Post by: Phils99 on September 28, 2014, 09:04:59 PM
...continued

Pic 1 and 2, first coat of satin black onto the scoops/air intakes and headlights

Pic 3 and 4, I then roughly masked up the fake engine (as this is the first layer and the other colours will go on top of this one)

Pic 5 and 6, this is the first coat of "aluminium" on the air vents and now also my hvac control panel!

Pic 7 fake engine with the rough masking removed, now ready for the next colours
Title: Re: Phils 4thirty build
Post by: Lee22 on September 28, 2014, 09:11:28 PM
Looking good Phil
Will be nice to see when you've got it done.

LeeC
Title: Re: Phils 4thirty build
Post by: Phils99 on September 28, 2014, 09:12:06 PM
Now onto the fake brake calipers...

Pic 1, Here are my parts, the fake brake calipers, bleed nipples, nipple covers and some brake lines

Pic 2, I drilled a hole for the brake lines, inserted and then bonded them on

Pic 3, I then fitted all the parts to all four calipers and mounted them on a piece of wood for spraying.

Pic 4, a closer look at the completed caliper

Pic 5 and 6, first coat of red caliper paint

Next, the steering wheel.....
Title: Re: Phils 4thirty build
Post by: MADMAN on September 28, 2014, 09:17:45 PM
all looking good Phil, love the HVAC unit, it makes it more a production look item.
Keep up the great work, you will soon be done and on the road
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on September 28, 2014, 09:20:54 PM
Pic 1, firstly, I drilled the hole for the horn, I made this so the horn fits losely, as I intent to get this part covered in leather.

Pic 2, 3 and 4, I then needed to fix the "airbag" part to the plate, I stole Paul79's idea here and, using a bent piece of metal strip, made a couple of brackets which will end up bonded to the "airbag" and then use these to screw to the plate.

Pic 5 and 6, I then wanted the leds to light up in the manetino switch, so I had acquired an old thrustmaster f430 steering wheel and decided to remove the switch and leds from this, firstly I cut the switch off the circuit board

Pic 7, I then removed the switch/led holder plastic from the back of the game wheel plate and also the graphic from the front as it is much nicer than the DNA supplied one (as is the switch!)

Pic 8, this is the cut off item assembled (without the knob fitted)

continued.....
Title: Re: Phils 4thirty build
Post by: Phils99 on September 28, 2014, 09:28:52 PM
...continued

Pic 1, I then drilled the hole in the plate for the switch, but, it wasnt long enough to attach the knob to..

Pic 2, so I had to shorten the posts which the switch circuit board sits on

Pic 3, I attached the graphic losely to check and added the knob and it looks cool!!

Pic 4, I then bonded the whole part to the back of the plate, I had to do some major trimming of what you see to get the steering wheel cowel to fit properley but I managed to get it in

Pic 5, After the bond had gone off, I stripped the part down and drilled the holes for the LED's

Pic 6, Finished switch in place, LEDs will light up with the ignition and the switch "switches" lovely with nice clicks! I also managed to carry out a bit of sanding of the cowel to get the start switch to fit from the rear so that its not sticking out to far, but never got pics of this, probably next time.......


Title: Re: Phils 4thirty build
Post by: Paul79 on September 28, 2014, 09:32:10 PM
NIIICE! I've got a winter project coming up!  8) loving that switch Phil.
Title: Re: Phils 4thirty build
Post by: Wizard on September 28, 2014, 09:51:26 PM
Phil, the quality of your work is very impressive. It's the attention to detail and extra special features that make these cars stand out.
Title: Re: Phils 4thirty build
Post by: rudycob1 on September 29, 2014, 05:21:41 PM
Looking good mate.
Title: Re: Phils 4thirty build
Post by: Phils99 on September 29, 2014, 06:27:51 PM
thanks for the comments guys, it means a lot and keeps me going!

Im really enjoying these bits as they are therapeutic, with the weather so nice on Sunday, I just pulled out a bench and chair onto the drive and sat in the sun sanding and prepping....lovely!

Also, I can experiment with these parts cos if I muck them up, its not such an expense to get a replacement....I also have the green machine as a donor at the moment!

I dont think I will be able to get the paddle shift working without fabricating special paddles for the MR2 wheel...that may be a job for another day.

Im also not happy with the "aluminium" spray paint as its very "runny" and doesnt cover very well, about as good as a "chrome" spray paint.

I may change these parts to a light grey as I think thats what it looks like on the real car

Here is the interior that I want to replicate, well almost! couldnt find exactly, but I would like similar to below except the seats, doorcards and A pillars will be creama leather, the carpet will be black, but I want the silver colour to the airvent surrounds, black leathered dashboard upper and lower, silver gear lever surround and a silver coloured plate for the ashtray and the other buttons.

Looking at the vent surrounds I guess they are silver in colour rather than aluminium!...think I will order some silver paint....
Title: Re: Phils 4thirty build
Post by: Phils99 on October 11, 2014, 09:54:16 PM
more painting today!

Pic 1, I worked out where I wanted the "FERRARI" stickers on the fake calipers and then applied them.

Pic 2, All 4 stickers applied, now I will apply a coat of laquer

Pic 3, OH NO! the laquer has reacted with the paint and ruined all my calipers  :-[ I will have to do them all again now

Pic 4, To take my mind of that mess, I turned to the fake engine, I masked up and sprayed the "metal" parts this time

Pic 5, after that had dried, I masked up to paint the air boxes

Pic 6, ...and then painted them red

Pic 7, Next, I moved onto the rear board that the fake engine is hinged on above the exhaust, earlier in my thread I had used a piece of "Dibond" to create the cover with and test fitted it and drilled all of the holes

Pic 8, I then covered this board with some nice carbon fibre wrap that I have had for about a year and not used yet! I like it!

That was it for today, hoping to get a few hours tomorrow......

Title: Re: Phils 4thirty build
Post by: beemaman on October 11, 2014, 10:06:02 PM
If you want to send your calipers over phil ile sort them for you and give them a good prime and red paint if it helps you out .)
Title: Re: Phils 4thirty build
Post by: Phils99 on October 11, 2014, 10:08:36 PM
cheers wayne....its not the end of the world I suppose...it just feels like it!

I have plenty of time, ill just do them again...
Title: Re: Phils 4thirty build
Post by: beemaman on October 11, 2014, 10:45:58 PM
If you need any advice buddy give me a shout.if its reacted buddy it needs 2k priming to seal in the reaction.aerosols won't be thick enough and too strong of solvents.

When's your car back phil ?
Title: Re: Phils 4thirty build
Post by: Phils99 on October 12, 2014, 09:16:30 AM
Cheers Wayne, somebody on here said you knew a bit about painting :-)

I am thinking car may be ready either next Saturday or Saturday after!!
Title: Re: Phils 4thirty build
Post by: Darren on October 12, 2014, 03:40:34 PM
Just a word of advice, Aerosol paints that are 'off the shelf' from your local car shop tend to be a little soft, the professional aerosol paints are of a much higher quality. They are at least double the price, but set harder and can take more abuse, little touch up jobs warrant the same quality paint as on the cars' body.
D
Title: Re: Phils 4thirty build
Post by: Phils99 on October 25, 2014, 07:53:20 PM
garage time!

Managed to actually get in the garage today and carried some more painting tasks...



Pic 1, I have now sanded and stripped back the fake calipers to repaint after bubbling....I primed them and resprayed them red....typical, I have now run out of the red paint and will have to buy some more just to finish these off....grrrrrr...I would have had enough!

Pic 2, fake engine now almost fully painted and all masking removed

Pic 3, I had previously cut out the grill pieces to go underneath the fake engine and I then sikflex'd them to the underside and left a but of weight on them to hold them in place.

Pic 4, view of fake engine from front with the lower mesh bonded, yes I know its diagonal in the middle and square on the outer edges, but I didnt have enough mesh left to do it the same!

Pic 5, I then bonded on the expansion tank cap I had bought, this was from an alfa romeo and was the nearest to the ferrari one I could find!

Pic 6, I then painted the ferrari word in the supplied cap which I had painted with aluminium paint.

Pic 7, I added the bolts and the jubilee clips, and then painted the "FERRARI" and horse on the air boxes, notice, I havent painted the "lines" as neither do Ferrari as shown in the picture I was working from, I find some builders do paint them and some dont, personal choice really!

Pic 8, a pic of the almost finished engine, I need to source some MAF plugs with cables and fit the side mesh yet.

Title: Re: Phils 4thirty build
Post by: Phils99 on October 26, 2014, 07:10:27 PM
Today was mainly just redoing my brake calipers aand pottering about doing little jobs here and there.

I then removed the masking tape from my air vents and assembled them to see what they look like and Im rather pleased!

Pic 1 and 2, here are the airvents assembled, I like the look of these!

Pic 3, garage all swept out ready for here return!
Title: Re: Phils 4thirty build
Post by: Furrari on October 26, 2014, 07:13:28 PM
Is that the floor I can see in the garage?
Title: Re: Phils 4thirty build
Post by: beemaman on October 26, 2014, 08:23:45 PM
They look great phil really good job on them will go great in car :)
Title: Re: Phils 4thirty build
Post by: Paul79 on October 26, 2014, 09:02:16 PM
Phil they look bloody awesome. Stop giving me ideas. So far I have resisted the dash conversion but I am weakening by the day!
Title: Re: Phils 4thirty build
Post by: cheets on October 26, 2014, 09:10:09 PM
Looking really good just hoping my dash will looks as good  Paul you just know you going to do it :)
Title: Re: Phils 4thirty build
Post by: rudycob1 on October 26, 2014, 09:11:43 PM
Everything you are doing looks fantastic.
This is going to be a great car.
Well done mate.
Love the dash idea.
Title: Re: Phils 4thirty build
Post by: MADMAN on October 26, 2014, 09:27:17 PM
Dash looks excellent Phil, I,m sure I,ll be copying your idea this winter 8)
Garage looks sad being empty, any idea when your baby is due to return?
MADMAN
Title: Re: Phils 4thirty build
Post by: Phils99 on October 27, 2014, 07:57:13 AM
Thanks guys for the comments

madman, I'm hoping it's this Saturday!!
Title: Re: Phils 4thirty build
Post by: MADMAN on October 27, 2014, 05:03:01 PM
Nice Phil, I,ve seen your car being painted, a lovely shade of yellow you picked
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on October 27, 2014, 08:24:32 PM
WHAAAAATTTTTTTT  ::) ::) ::) ::)
Title: Re: Phils 4thirty build
Post by: Furrari on October 27, 2014, 11:02:11 PM
I'm glad somebody knows what colour a Furrari should be.  :-)
Title: Re: Phils 4thirty build
Post by: MADMAN on October 27, 2014, 11:35:45 PM
I'm glad somebody knows what colour a Furrari should be.  :-)
            Yup Phil knows exactly what colour a Furrari should be, nice choice Phil ;)
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on November 07, 2014, 08:00:47 PM
Well, the day is almost here, yes I pick up my baby tomorrow from DNA!!

...just hoping I can beat the rain it looks like it will be chasing us back up north!
Title: Re: Phils 4thirty build
Post by: Phils99 on November 08, 2014, 02:50:43 PM
Well, all I can say is, it couldnt have rained any harder if it tried...ALL THE WAY HOME....ah well, at least my baby is al tucked up in her garage now :-)
Title: Re: Phils 4thirty build
Post by: MADMAN on November 08, 2014, 02:58:41 PM
Hey Phil, I can feel you grinning from here ;D ;D
Looks great, now you can crack on and finish your baby.
Love your colour choice  8)
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on November 08, 2014, 03:01:38 PM
choice? I didnt have a choice, there is only one colour for a Ferrari :-)
Title: Re: Phils 4thirty build
Post by: beemaman on November 08, 2014, 03:20:44 PM
Looks nice phil bet your glad its home now so you can start tinkering :)

Soon be together and be ready for next year :)
Title: Re: Phils 4thirty build
Post by: Wizard on November 08, 2014, 05:08:31 PM
Fantastic, looks good. I bet you attracted lots of attention on the way back home.
Title: Re: Phils 4thirty build
Post by: Phils99 on November 08, 2014, 05:32:41 PM
i dont think you could see the car through all the road spray!!
Title: Re: Phils 4thirty build
Post by: Furrari on November 08, 2014, 05:40:59 PM
We tried your rear wing on The Furrari.  It might suit your 430 but it looks totally wrong on a West Coast., but one is a sports car and the other is a GT.
Mick
Title: Re: Phils 4thirty build
Post by: ferrari feb 14 on November 08, 2014, 11:23:40 PM
Looking great phill,now you can enjoy putting her back together ,looking forward to seeing it at the shows ,jd
Title: Re: Phils 4thirty build
Post by: cheets on November 09, 2014, 12:15:03 PM
Looking good  phil looking forward to seeing the rest of the billed :)
Title: Re: Phils 4thirty build
Post by: Phils99 on November 09, 2014, 08:49:48 PM
so ,with the super shiny car sitting in the garage...its so nice i darent touch it!!

I thought I would start simple and see how I get on when I stop being scared of scratching it!

Pic 1, refitted the front scuttle to check the gap for the air intake part and its now a bit closer so I cut some more off to make sure the edge of the bonnet doesnt catch it, I then taped on the front bit I had previously removed what seems like years ago!!

Pic 2, I then turned it over, mixed up some P40 and bonded the front part onto the scuttle

Pic 3, it now just leaves a small gap which I will fill with filler

Pic 4, I decided to start working on the car from the rear, so I jacked it up onto axel stands, removed the wheels and rear diffuser for access and fitted the rear lights, reflectors and license plate holder

Pic 5, I then unwrapped the 4 diffuser fins from the bubble wrap and realised that I didnt know which one went where as I hadnt numbered them :-( , so trial and error, I tried the first one into all 4 positions until I could get all the screws through the holes into the fin, I did this for each one until I had all 4 fitted, I then laid it down to look at it....I love it! so glad I had it done like this now, it will look the dogs when its back on the car!

Pic 6, this is the look im after, later on, I would also like to add the extra cross piece, a project for the future....
Title: Re: Phils 4thirty build
Post by: Furrari on November 09, 2014, 11:26:00 PM
Looks very aggressive but I have my doubts about the ground clearance on the outer edges of the Hamann diffuser, but I suppose it's that close to the rear wheel it's protected.
Title: Re: Phils 4thirty build
Post by: cheets on November 09, 2014, 11:59:33 PM
Looking good Phil
Title: Re: Phils 4thirty build
Post by: Phils99 on November 10, 2014, 11:58:39 AM
Furrari, I think you will be right about the ground clearance, but this is due to the fact that Hamann also lower the car, mine wont be any lower than the normal diffuser.
Title: Re: Phils 4thirty build
Post by: ghall164 on November 10, 2014, 08:26:25 PM
 :o she's going to look great
Title: Re: Phils 4thirty build
Post by: sha121 on November 11, 2014, 10:30:28 AM
She is looking really good
Title: Re: Phils 4thirty build
Post by: Phils99 on November 16, 2014, 07:35:10 PM
had a good day on her today

Pic 1, Started to sort the headlight housing out so firstly, I covered the lenses in cling film to stop them getting scratched

Pic 2, I then taped the lense to the headlight housing with masking tape

Pic 3, I then drilled a small hole to get it correct and then made it larger

Pic 4, I then fixed a fat head screw and bolt into the hole.

Pic 5, this was then repeated for another 5 times so that I had 6 bolts holding them together

Pic 6, I then took this unit into the garage and using the grinder, trimmed off the excess lense so that it matched the shape of the headlight body, this makes it easier to insert through the headlight hole in the wing when fitting, cling film removed!

Title: Re: Phils 4thirty build
Post by: Phils99 on November 16, 2014, 07:48:41 PM
So now I decided to put to bed a job I have been putting off for ever.....the exhaust.

I think most recent buildrrs will agree with me that the exhaust is probably the worst part of the kit as mine just didnt really fit together at all, the pipes that went inside the other pipe had such a large difference in size, you couldnt clamp them together with the U clamps, even after putting slits in the side.

SO, having thought about this, I decided to cut some thin pieces of metal into "shims" and slip then down the gap inbetween the 2 pipes when fitted inside one another, I didnt get any pics of these, but my goal was to get the exhaust tight enough so that it almost stays in the correct position without the exhaust mounts in place, as it should as the mounts are just really there to allow flexing of the exhaust due to engine movement when excellerating etc.

Using the shims, this worked a treat, I managed to fully tighten the exhaust using the U clamps so that it didnt move about like it use to. After a little shortening of one of the down pipes, I was well pleased and managed to get the tips into the exact position that I want them to be!

I will use loads of exhaust paste to seal them, but at the moment, I will have to remove the tips to get the exhaust shrouds in place, which I aim to do next week.

I also started on the fuel filler solenoid mounting and had to fit my Hamann badge!

Pic 1, Both tips solid and exactly in the posittion I want them (the car is on axle stands at the rear for access through the wheel arch)

Pic 2 and 3, Close up of the tips postions

Pic 4, Hamann badge fitted

Pic 5, Made a couple of brackets for the fuel cap solenoid

Pic 6, this is where it will be bonded

Title: Re: Phils 4thirty build
Post by: Paul79 on November 16, 2014, 08:08:40 PM
Well done matey on the exhaust. I know it's been a b*gger for you. Looks great now.
Title: Re: Phils 4thirty build
Post by: ghall164 on November 16, 2014, 10:44:07 PM
Loving the hamann touches :o
Title: Re: Phils 4thirty build
Post by: cheets on November 17, 2014, 01:31:22 AM
looking good Phil thing i am going to do the same with the fuel cap for the exhaust i am going to have to get the pipes rey made i just can not get them to fit
Title: Re: Phils 4thirty build
Post by: Phils99 on November 17, 2014, 08:04:32 PM
Yea the pipes are pants with lots of kinks in them where the bends are.... I was gunna get mine on the road and then take it to an exhaust place to get new pipes fabricated.
Title: Re: Phils 4thirty build
Post by: cheets on November 17, 2014, 08:35:14 PM
yes think the ones i have are the same got a mate that make new stands exhaust only thing is i need to get to him so he can mack the pipes was going to get him to de cat it as well :)
Title: Re: Phils 4thirty build
Post by: Phils99 on November 17, 2014, 10:07:17 PM
I did the decat early on in my thread, its easy just remove the manifold and smash the cat out!
Title: Re: Phils 4thirty build
Post by: cheets on November 18, 2014, 12:54:12 AM
I did one better got a tubular manifold two get rid of the pre-cats i keen the mane cat
Title: Re: Phils 4thirty build
Post by: Phils99 on November 22, 2014, 07:03:27 PM
so..today was bonding day!

Pic 1, As advised by Paul, I released the rear deck gas rams so that the rear deck would open wider to enable me to fit the top mesh piece easier, make sure you put lots of cloths to stop the rear deck rubbing on the rear of the car when fully open.

Pic 2, First I refitted the mesh above the diffuser and the one above this, but I didnt get any pics of it...

Pic 3, then I had to remove the exhaust tips so that I can fit the surrounds

Pic 4, using some thin pieces of wood, I wrapped them with a cloth and then used tie wraps to hold the side air intake meshes in place

Pic 5, View from the rear of the side lower air intake being bonded, when it goes off I will see if it needs any more to hold, but I think this will be enought

Pic 6, I then used the same retaining method for the exhaust surrounds...

Pic 7, view from the front of the exhaust surround.

As careful as I was this black stuff gets everywhere! keep plenty of clothes around to remove any excess whilst its still soft, as, when it goes hard, its a nightmare to remove!

I will check all these have bonded ok tomorrow and refit the exhaust tips, hopefully for the last time, the rear end is coming along nicely!
Title: Re: Phils 4thirty build
Post by: Lee22 on November 22, 2014, 08:05:33 PM
Looking good Phil.

Can you tell me where you bought your mesh from please?

I have no mesh under the rear number and above the rear diffuser, and I would to fit some, but I can't find where to get I from

Thanks in advance
Lee
Title: Re: Phils 4thirty build
Post by: Phils99 on November 22, 2014, 08:21:35 PM
you get all the different types of mesh (3 sizes) supplied in the kit mate....

If you ask nicely, im sure someone on the forum has some left that you could use, you done need a big pice to do the bit above the diffuser, or maybe DNA can supply you a small piece to do the job with?
Title: Re: Phils 4thirty build
Post by: Lee22 on November 22, 2014, 08:30:41 PM
Oh, ok Phil...

Thanks for the reply.

I'll keep looking :D
Lee
Title: Re: Phils 4thirty build
Post by: MADMAN on November 22, 2014, 11:23:37 PM
Hey Lee, post a pic of type and dimensions, I may have enough for what you need
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: beemaman on November 22, 2014, 11:25:27 PM
I've got some lee don't panic :) ile cut you a piece Monday when I get difusser out if booth :)
Title: Re: Phils 4thirty build
Post by: MADMAN on November 22, 2014, 11:41:51 PM
Sorted, great owners club ;)
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Lee22 on November 23, 2014, 12:01:49 AM
Wow guys....  Thanks you..!

Cheers madman from the offer mate, that's very much appreciated.

I'll take you up Wayne on that if its ok, as I'll be down hopefully next weekend to collect the diffuser and front spliter.

Thanks again guys.... What a group of great people ;D

Lee
Title: Re: Phils 4thirty build
Post by: Phils99 on November 23, 2014, 01:11:12 PM
I knew they would come through for you mate!
Title: Re: Phils 4thirty build
Post by: Lee22 on November 23, 2014, 04:55:13 PM
There's some great people on this forum  ;), and it be wrong of me to name them, but you all know who ive been constantly talking to over the last few months.... And I would like to say a big thanks to them all.

I feel like one of the crowd already... Which is great, to say I'm so new to you all.

What a difference to 19 years of being in the Westfield club; You could never break into that 'click'...
Title: Re: Phils 4thirty build
Post by: Phils99 on November 23, 2014, 08:27:05 PM
Another good day on the car

Pic 1, I used the tiger seal to fix the wires into the high level brake light

Pic 2, I then fitted a superseal plug onto the light so that its easily removable in the future

Pic 3, Light installed and plugged in

Pic 4, put the exhaust tips back on after fitting the exhaust surrounds, looking nice!

Pic 5, back onto the rear mesh, the real car has the rear deck lock behind the mesh and so you see a black plate, I am emulating this by boinding this plate behind the mesh, I can then use this to also mount the prancing horse onto later.

Pic 6, Whilst I had the tiger seal out, I also bonded on the Silver cap to the fake engine

continued...
Title: Re: Phils 4thirty build
Post by: Phils99 on November 23, 2014, 08:35:40 PM
...continued

Pic 1, I then bonded on the solenoid and brackets I will be using for the fuel cap release

Pic 2, I need to add an emergency release for the fuel cap in case the solenoid stops working, to do this I took the fuel cap release plunger...

Pic 3, and drilled another hole in it

Pic 4, here is the solenoid connected to the fuel cap plunger and the emergency release cable attached

Pic 5, I then made a small bracket for the release end which will be available through the number plate cut out same as the emergency rear deck release levers

Pic 6, I then bonded on the air intake meshes on both sides...front view

Pic 7, rear view

Roll on next week to get more done! rear nearly done,  so I will be removing the front bumper soon to do all the front bits...
Title: Re: Phils 4thirty build
Post by: cheets on November 24, 2014, 08:48:25 PM
Hi Phil loving the work just one thing to ask on the fuel flap release is the spring in the catch strong enough to pull the motor in the CENTRAL LOCKING unit back as i am doing the same but was thing of  using a solenoid ?

mark
Title: Re: Phils 4thirty build
Post by: Phils99 on November 24, 2014, 11:27:51 PM
I guess you mean the spring in the catch of the fuel flap? I would think so, its pretty strong, but the solenoid you see in the pic pulls it easily...
Title: Re: Phils 4thirty build
Post by: cheets on November 25, 2014, 07:04:55 PM
nice one Phil i am hoping to get min dun wen i get back i if i get chans  to work on it :)
Title: Re: Phils 4thirty build
Post by: Paul79 on November 25, 2014, 10:13:30 PM
Nice Phil. Just on your grills now that they are fixed in place add loads more bond glue all around the edge to make them super strong. These have the potential to get knocked and pushed in I reckon so the more secure they are the better. It would break your heart if u accidentally knocked one and it got pushed in.
Title: Re: Phils 4thirty build
Post by: Phils99 on November 30, 2014, 07:54:25 PM
manged just half a day on her this weekend so decided to work on the front bumper

Pic 1, removed the bumper to make it easier to work on

Pic 2, I bonded on the side grills, I had previous cut these out and shaped them correctly so all I had to do was squeeze the black stuff to hold it!

Pic 3, I held them in place with tie wraps and piece of wood wrapped in cloth, view from the front

Pic 4, I then fixed the splitter in place, this has been painted black to again acheive the Hamann style

Pic 5, I then unpacked the front part of the Aero kit and had to then drill holes for the mounting bolts in the parts and also through the bumper.

Pic 6, Lining up the holes with the bumper for drilling, I then fixed the Aero to the bumper with 3 bolts




Title: Re: Phils 4thirty build
Post by: Phils99 on November 30, 2014, 08:04:51 PM
I then did the same on the other side of the bumper and it finished up looking really good the black running right across from one side of the bumper to the other this car is gunna be low! better avoid all speed bumps :-)

Pic 1, side view of bumper with aero parts fitted

Pic 2, high up view from the front!

Pic 3, When I picked the car up, it was full of dust, and as it was raining for the journey home, the interior is a mess! I decided to do a bit of cleaning up! check out the difference between the passenger and drivers side! Ill do the drivers side another day.....
Title: Re: Phils 4thirty build
Post by: beemaman on November 30, 2014, 09:31:05 PM
Nice work phil

Hope it's going to be at stoneliegh buddy :)
Title: Re: Phils 4thirty build
Post by: ferrari feb 14 on November 30, 2014, 11:24:38 PM
Great job phill luv the front spliiters ,at this pace you should defo be ready for the first shows ,jd
Title: Re: Phils 4thirty build
Post by: Furrari on December 01, 2014, 09:10:55 AM
Phil.  Dust?  I thought that was carpet.  Mix it with resin, make a good soundproofing. :-)
Title: Re: Phils 4thirty build
Post by: Phils99 on December 04, 2014, 09:44:57 AM
no update on car, but relevant.....

I start a new contract role on Monday for a company that is 27 miles from my house and will be leaving London! the nearest I have been in many years!

This will mean I will be home every night and can get to do those little jobs on the car through the week...I will also save £1000 per month on travel and accommodation costs, which can now go towards finishing my car!

well pleased!
Title: Re: Phils 4thirty build
Post by: beemaman on December 04, 2014, 09:50:29 AM
woooooooo thats great news phil im excited and its you whos working closer :)

cant wait for updates now bddy be at shows next year for sure now :)
Title: Re: Phils 4thirty build
Post by: Phils99 on December 04, 2014, 10:26:04 AM
That is my plan, to actually turn up with my own completed kit car instead of the green machine! (which is still sitting on my drive all sad :-( )

Really looking forward to next years shows.....
Title: Re: Phils 4thirty build
Post by: Furrari on December 04, 2014, 10:45:49 AM
It will be good to see your finished car at shows, but we need the green machine as well.
Title: Re: Phils 4thirty build
Post by: Wizard on December 04, 2014, 11:05:05 AM
Congrats on the new contract.

Saving £1k a month. Wow, u can do a V6 conversion by the summer will all those saving. Lol
Title: Re: Phils 4thirty build
Post by: Phils99 on December 04, 2014, 11:22:11 AM
hmmmm tempting!
I may just stick with the 1.8 engine as this will be my show car, I have the Porsche for when I want real speed!!
Title: Re: Phils 4thirty build
Post by: Phils99 on December 06, 2014, 07:46:54 PM
BLOODY FREEZING!
Thats how I would some today up!

Day started with a skiing lesson in an indoor real snow skiing place, then followed by me working in the freezing garage!

Anyway, I have so many jobs left to do and some of them you cant do until you have done something else etc etc, so I juts went in there and see what jumped out at me! First thing was the prancing horse to finish off the rear end. then a bit more work on the front bumper followed by fitting the washer bottle (related to the front bumper I guess!)

Pic 1, The length of the threads on the back of the prancing horse are very short, so I had to test with an offcut of mesh and a piece of plastic. The nuts only just go on, but I will bond it on as well anyway. here are the holes drilled in the "plate" behind the mesh

Pic 2, and the prancing horse in place

Pic 3, moving onto the front bumper, here is the air intake mesh bonded in place on one side

Pic 4, and the other side...

continued....
Title: Re: Phils 4thirty build
Post by: Phils99 on December 06, 2014, 07:56:06 PM
So now onto the washer bottle, I had previously cut the neck off and created a fitting for it under the bonnet, I just needed to fit the main bottle in place.

Pic 1, Firstly, I made the hole in the headlight mouting bracked larger so that the washer bottle will be able to "poke" through and sit nearly vertical, it actually sits at a slight angle but it should be OK.

Pic 2, I then drilled two mounting holes and got out the rivnut tool again to create the 2 rear mounting points for the washer bottle

Pic 3, I was hoping that these would be enough, but, the bottle does move a little, so I made a bracket to take the front mounting hole, its now solid!

Pic 4, here is the filler cap neck under the bonnet, just need a short piece of rubber tube now to connect them together!

Pic 5, I then painted under the light bracket black where I had cut the metal and then painted the washer bottle black, as otherwise it would be seen through the air intake.
Title: Re: Phils 4thirty build
Post by: Phils99 on December 08, 2014, 08:49:50 PM
managed to get half a day on sunday, i was constantly doing things but they all were just little bits, I managed to use the P38 filler on the scuttle after testing the fit as the bonnet has been realigned by DNA, it needed a little bit of modification to get it to fit so that the bonnet didnt touch the front grill I had reattached, I also use exhaust paste to seal the exhaust from blowing through the poor joints.

I then got another bucket of water and did more cleaning under the rear deck and the bonnet as they were all dirty.

I love what DNA have done with the paint job, they have used the textured black paint underneath the bonnet and rear deck and I love the finish.

Pic 1, here is the scuttle with the filler applied, just need to sand it now when its dry

Pic 2, under bonnet frunk area all cleaned up

Pic 3, under rear deck all nice and clean
Title: Re: Phils 4thirty build
Post by: Phils99 on December 12, 2014, 08:46:35 AM
Let me be the first to say many many thanks to all of the wonderful people on this forum who have assisted and inspired me to do this build, without this forum and its members, I would not have got as far as I have with this build.

Looking forward to meeting and spending time with many of you in the new year at the car shows, roll on 2015 where I will have MY car and stop being that "hanger on"!!

Thanks again to all of you and all thats left to say is:

Title: Re: Phils 4thirty build
Post by: Furrari on December 12, 2014, 10:09:16 AM
Phill.  Never a hanger on.
Title: Re: Phils 4thirty build
Post by: beemaman on December 12, 2014, 07:41:21 PM
Merry Xmas to you too phil and looking forward to seeing you and your car at the shows too.

Going to be a great year 2015 :)
Title: Re: Phils 4thirty build
Post by: Phils99 on December 14, 2014, 08:09:08 PM
another cold day in tbhe garage today, but managed to get a few things done....

Pic 1, Found this at Toolstation, its the perfect part to use to extend the washer bottle!

Pic 2, To get it to fit, you will have to grind down the lip on each side of the pipe on the washer bottle....

Pic 3, ...and then it fits nicely!

Pic 4 and 5, add a couple of jubilee clips and this is the finished item seen from under the bonnet and through the light hole

continued....

Title: Re: Phils 4thirty build
Post by: Phils99 on December 14, 2014, 08:19:16 PM
I had taken delivery of various size and lengths of roof bolts. I like these as they have a flat head, so I replaced the previous bolts I had use to fix the front bumper aero kit on with the roof bolts

Pic 1, front bumper aero kit secured using roof bolts

Pic 2, I then moved on to fit the rear side aero kit parts, these give the car a different look, I love them!

Pic 3, I decided that for now, I had finished under the rear of thecar and so refitted the rear diffuser, replaced the rear wheels and put the rear of the car back on the ground

Pic 4 and 5, Next, I bonded on the front bumper scoops, Ive added Sikaflex where I can get it to bond, but I think I may use some P40 to give it a bit more strength later on.

Pic 6 I then sanded down the scuttle and added some masking tape to protect the rubber bits from the paint

Pic 7, I then used textured bumper paint (good tip Beemaman!) to paint the scuttle and give it a nice clean look, I will fit this part next time and sort out the wipers and washers.

All in all, considering the cold, it was another good day and some more items ticked off the list!
Title: Re: Phils 4thirty build
Post by: cheets on December 14, 2014, 11:01:11 PM
Looking good Phil can not what to get mine  in pant  :)
Title: Re: Phils 4thirty build
Post by: ferrari feb 14 on December 15, 2014, 07:51:21 AM
Coming together nicely now phill looks great ,jd
Title: Re: Phils 4thirty build
Post by: ghall164 on December 15, 2014, 05:50:03 PM
 :) nice work love the aero kit can't wait to see this finished  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on December 15, 2014, 08:28:46 PM
add a quick hour in the garage tonight,so..

Pic 1, I first took the maf sensor plugs that Mario sent me (cheers mate!) and added some cable from an old SCART lead (I cut the plugs of Madman!) to give them some length, Ill fit these to the fake engine later

Pic 2, I then refit the front bumper and she looks so mean and low!!

Pic 3, another pic, just need to fit the front sill part of the aero kit to complete the "black surround"!

May get some time again tomorrow night...
Title: Re: Phils 4thirty build
Post by: MADMAN on December 15, 2014, 09:23:58 PM
Scart plug ;D ;D ;D say no more
MADMAN ;) ;)
Title: Re: Phils 4thirty build
Post by: cheets on December 15, 2014, 10:05:03 PM
Hi Phil

on you solenoids for your deck release i am have i bit of a problem with one of them not releasing all the time how are you getting on with yours ?
Title: Re: Phils 4thirty build
Post by: beemaman on December 15, 2014, 10:16:33 PM
Looking good phil keep the work and pics coming buddy :)
Title: Re: Phils 4thirty build
Post by: Phils99 on December 16, 2014, 08:19:18 AM
cheers guys!

cheets, I had to alter the rear deck latching pins ( the ones that lock into the catches) to take some pressure off otherwise the solenoid wouldnt release, I havent tested them since getting the car back, ill see if I get chance to test them tonight.
Title: Re: Phils 4thirty build
Post by: cheets on December 16, 2014, 07:39:39 PM
Thanks Phil think i have dun it set the catch and pin and all seems to be ok will check to morrow but looking good to day

Not dun much to day well would say not got seemed to get a lot dun lol 

Title: Re: Phils 4thirty build
Post by: Phils99 on December 16, 2014, 09:20:39 PM
another cold hour or so in the garage!

I reinstalled the scuttle this time.

Pic 1, As Beemaman did on his build many moons ago, I used the number plate screw caps to cover the scuttle securing screws as I think it looks nicer than the screw heads...this is the type of cap I mean..

Pic 2, and when its closed....

Pic 3, I then dug out the wiper blades and refit them, these were probably one of the first things I removed when I stripped the car down, they havent been on for 2 years!!

Pic 4, I then rechecked the fit of the frunk surround, as I didnt have the "twist" brackets fitted when I originally cut it out and I had to make some minor adjustments, I then sprayed it with the textured paint and will fit this and the washers next time, maybe weekend as I have xmas shopping to do one night this week!
Title: Re: Phils 4thirty build
Post by: cheets on December 16, 2014, 11:10:50 PM
Nice Work Phil loving it  :)
Title: Re: Phils 4thirty build
Post by: Paul79 on December 17, 2014, 07:18:09 AM
The scuttle cover looks great matey. Glad yours turned out right first time (unlike mine) but what about your washer jets? Don't forget those.
Title: Re: Phils 4thirty build
Post by: Phils99 on December 17, 2014, 08:33:13 AM
Cheers guys,

Paul, washers are on the cards next time I get in the garage!
Title: Re: Phils 4thirty build
Post by: Phils99 on December 19, 2014, 08:44:51 PM
not too cold tonight!

I decided to change my washers to be fixed onto the scuttle instead of clipped on the wipers, so I cut out a couple of holes in the scuttle and after a bit of shaping and filing I managed to get them to fit nicely...

Pic 1, the original washer jets fitted into the scuttle

Pic 2, this left a hole in the scuttle I had drilled for the washer tube now not required...

Pic 3, ...luckily I found this bung in my vast collection of fittings and plastic bits...

Pic 4, which plugged the hole perfectly!

Pic 5, This is how I have run my washer pipes under the scuttle

Pic 6, after fitting the front closing panel, it looked wrong as it was shiny black plastic, so I sprayed this with the textured bumper paint to match the rest of the frunk area...

Next time, I need to check my doner car to work out which clips go where under the frunk!
Title: Re: Phils 4thirty build
Post by: Phils99 on December 21, 2014, 08:43:30 PM
Very productive day today, I wanted to fit my mirrors, but couldnt until I had put the glass back in my doors to check the fit, but I couldnt put the glass in until I had wired up the door lights I am fitting...so I decided to do the door lights as my main job...

Pic 1, I started by fitting the exhaust cover...

Pic 2, so that I could bolt on the hinges for the fake engine. I was going to add strings so that the engine lifted with the rear deck, but I never got round to that bit yet!

Pic 3, As I want to do my mirrors soon, I decided to fit the electric mirror adjusters into the mirror body, so firstly I roughed up some areas...

Pic 4, and then applied the bond, I then pushed in the motorised part but forgot to take a picture of this bit!

Pic 5, I then got the bucket and cloths out and cleaned the drivers side, and I had to change the water 3 times! it was minging!

Pic 6, so....starting on the wiring for the door lights, I first needed to get 2 wires into the actual door to power the lights I found the easiest way to do this is to remove the wheel to access the rubber bungs from under the wing, I pulled the rubber tube out and then threaded a stiff wire through...

Pic 7, this then enabled me to then pull through my wires through the rubber part

Pic 8, I then threaded my stiff wire into the car to get the wire inside the car itself.

continued......
Title: Re: Phils 4thirty build
Post by: Phils99 on December 21, 2014, 09:00:12 PM
...continued

Pic 1, and with the wire now inside the car, I replaced the grommets back into the door and the car body

Pic 2, so I then wired up the original ferrari light I had bought

Pic 3, I had previously drilled a hole in the original MR2 door so that I can get the ferrari light wiring into the MR2 door

Pic 4, I also fitted the projector light in the bottom of the door and connected this wiring to the ferrari lights wiring

Pic 5, I then tested them before I completed the wiring! this picture is rubbish, they actually look brilliant in real life!

Pic 6, for anyone doing this, you will need to connect a permanent battery to one of the wires and also you need to connect the door switch wire to the other wire from your lights. I traced these wires to the bottom of this connector and the red wire bottom right of the plug is the other end of the door switch and the wire next to it had a permanent battery on it! so I connected both my wires to this plug and it all works a treat when you open and close the door, well pleased!
Title: Re: Phils 4thirty build
Post by: rudycob1 on December 21, 2014, 09:39:55 PM
It's coming together now mate.
Looking good. Looking forward to seeing it at the shows in 2015.
Title: Re: Phils 4thirty build
Post by: Phils99 on December 22, 2014, 09:01:51 PM
cant beleive how warm it is! got straight home from work and straight in the garage for the last time until after xmas!

Pic 1, I fitted the door windows

Pic 2, and replaced the carpet into the car

Pic 3 and 4, I then reattached the pods and added the p rubber around the edges

Pic 5, After putting p rubber on, I wasnt happy with it so I removed it and did it a different way and it looked much neater, it looks neater when you apply the long piece onto the front of the rear deck as shown, then apply the other bits as required.

Pic 6, I then removed the brackets I had made to strengthen the roll hoop surround and applied bond onto them

Pic 7, these brackets fit here to add the strength

Pic 8, I then dug out the Z flaps and reattached them, all looking pretty good at the moment!

Merry xmas all, and see you with more updates after Xmas!
Title: Re: Phils 4thirty build
Post by: Wizard on December 22, 2014, 10:48:43 PM
Wow, this build is progressing very quick.  You will certainly have a very good 2015. Keep up the excellent work (while the weather holds off). 
Title: Re: Phils 4thirty build
Post by: Paul79 on December 22, 2014, 11:09:08 PM
Merry Christmas Phil. Great work on your build. Looking forward to see it it finally done early next year. Following your updates with much enjoyment. Brings back fond memories for me.  ;D
Title: Re: Phils 4thirty build
Post by: Paul79 on December 22, 2014, 11:12:19 PM
Btw. On the long piece of p rubber you used on rear deck, you'll probably want go cut it away where the roof straps go to create a gap. You'll find if you don't , the straps will rub and tear the p rubber. I cut gaps out and then replaced with thinner rubber. I'll send you a picture next time I'm in the garage.
Title: Re: Phils 4thirty build
Post by: Phils99 on December 23, 2014, 07:06:43 PM
I lied! managed to get an hour on it tonight as got off from work early!

All i had time to do was test the electric motors in the mirrors to make sure they dont catch on the inside of the mirror, one of them did so I cut the plastic down a bit to stop it, after that I lined up the mirrors using some cardboard spacers and bonded them on.

I then placed a weight on ech one to press them down and will leave these to set

Pic 1, mirror all lined up with cardboard

Pic 2, mirrors bonded with weight on top
Title: Re: Phils 4thirty build
Post by: beemaman on December 23, 2014, 07:16:30 PM
Great work buddy :) coming on really good now you will be there in no time :)

You using removable mirror plates buddy
Title: Re: Phils 4thirty build
Post by: Phils99 on December 23, 2014, 07:32:47 PM
cheers wayne, I will probably not use the mirror brackets as I wanted it a bit closer fitting, also, not bothered about removable mirrors as my garage is big enough now!

Got my spare key back from DNA so I will send you my remote key in the new year...all the best for xmas and new year mate.
Title: Re: Phils 4thirty build
Post by: Paul79 on December 24, 2014, 09:32:19 AM
Phil. Here's the picture on the rear deck p rubber I promised. I cut gaps in the p rubber and then replaced with thinner flat pieces of rubber. This way there is more room for the roof straps plus they won't rub on the paint whilst also maintains the black continuous rubber look

Title: Re: Phils 4thirty build
Post by: Phils99 on December 28, 2014, 04:50:26 PM
nice one Paul, ill look at that when I do my roof....
Title: Re: Phils 4thirty build
Post by: Phils99 on December 28, 2014, 05:01:47 PM
went into the garage today and it was FREEZING!

Managed to get a few bits done:

Pic 1, Roughed up the mirror mounting piller ready for bonding on the mirror

Pic 2 and 3, tip for new builders, the plug on the end of the mirror motor can be removed, meaning that you dont need to cut a hole/channel  on the inner side of the piller, you thread the cable through and route it to the front of the door and around behind the metal channel for the door glass, bringing it back into the door to the socket it needs to clip in to, you can see the black wire from the inside of the door here, I then bonded the mirror on and clamped it until it goes off (Ill leave this for a day or 2 due to the cold weather)

Pic 4, I then fitted the passenger side front sill aero kit part, this was a pain, as I had filled my sills with expanding foam and so had to dig a load of it out to get the nuts and bolts in to hold it on

Pic 5, I then started work on my fake door locks, I had drilled a large hole in a washer and slotted the lock through, I have then bonded the back of the washer to the lock and left to set. When this is done I will look at bonding the washer to the inside of the door therefore holding the lock in place.
Title: Re: Phils 4thirty build
Post by: beemaman on December 29, 2014, 09:27:55 AM
hi phil

have you bonded on mirrors yet ? i have a last pair of mirror plates like rudy has on his car so that mirrors can be removed if you want them there onkly sitting here doing nowt :)
Title: Re: Phils 4thirty build
Post by: Furrari on December 29, 2014, 09:46:24 AM
Phill
I know what you mean about freezing.  Mechanical work on The Furrari has stopped until you can't see your breath in front of you.  The heat from a 35 W soldering iron doesn't help a lot.
Title: Re: Phils 4thirty build
Post by: MADMAN on December 29, 2014, 04:05:34 PM
before I got a space heater, I,d start car and run it to temperature then close garage door and open bonnet, surprising how much heat you have there ;D
But the space heater spoils you, I have worked in my tee shirt when it,s frosty outside, down side is the cost of gas aprox. £55 for a 47kg bottle :o :o
I could do with a contact in Pontefract area with cheap bottles of gas ;) ;)
Car coming on Phil, it,s looking good, better now you are at home all week.
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Furrari on December 29, 2014, 04:32:07 PM
Madman, I never thought of that.
Title: Re: Phils 4thirty build
Post by: Phils99 on December 30, 2014, 07:18:33 PM
hey guys,

looking through other build threads I noticed that some have a rubber part bonded onto the Z flaps (like you have madman) where do you get this rubber bit from? is it part of the original MR2? if so where from? picture below of what I mean....
Title: Re: Phils 4thirty build
Post by: beemaman on December 30, 2014, 09:10:17 PM
It's from DNA buddy
Title: Re: Phils 4thirty build
Post by: Lee22 on December 30, 2014, 10:29:45 PM
Good luck in getting a set phil,

I rung Roland a few times about them, when I first bought the car, as mine are all chewed up, (due to the fact the roof had been raised on mine a few times without these flaps being moved out of the way enough) so i wanted to replace them with new ones.

After a fair bit of toing and froing on the phone, Roland said they don't have any and wouldn't be getting any more, as to make it cost effective he has to have a fair few sets made.
So I never got a replacement set.

Hence I'm in discussions with Barry (Mario) now to see if we can make some out of another material and get them sprayed Matt black.
Plus, at the same time, I will be making the shape of these slightly bigger to disguise the gaps a little better, as I think these are just a little too small (IMHO)

As you can see from the attached picture... Not moving the Z flaps out of the way PROPERLY creates this gnarled mess of them.


Lee
Title: Re: Phils 4thirty build
Post by: Phils99 on December 30, 2014, 11:49:52 PM
brilliant Lee! keep us posted mate
Title: Re: Phils 4thirty build
Post by: Lee22 on December 30, 2014, 11:56:42 PM
Will do..  ;D

Although it's not on the top of my list of jobs to do.....!

And believe me, this list is getting longer ever weekend I go to Barry's to 'play' with the car....
Title: Re: Phils 4thirty build
Post by: MADMAN on December 31, 2014, 09:35:19 AM
hey guys,

looking through other build threads I noticed that some have a rubber part bonded onto the Z flaps (like you have madman) where do you get this rubber bit from? is it part of the original MR2? if so where from? picture below of what I mean....
As beemaman said DNA supplied them with kit. Looking good Phil,
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Wizard on December 31, 2014, 02:46:04 PM
Phil, you have made excellent progress considering how cold it is outside. Can't wait to see your car next year.  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on January 01, 2015, 07:37:50 PM
well, as I didnt go out last night, I was up and in the garage for 9am this morning as it was much warmer than it has been!

Pic 1, I prepped the door part and added the sticky stuff to the passenger mirror to be bonded, I then bonded and clamped this on and will leave a couple of days to set. The drivers door seems good, but I will add some P40 to both mirrors later for extra bond

Pic 2, Fitted the T plates and thumbwheels, I will add a plate across this to set the max high required after I have fit the roof

Pic 3, It was rear glass bonding time!!! I bought one of these glass suckers cheap from tool station, perfect for one man lifting to check the fit and to lay it on the sticky black stuff....although I did test lifts with it an inch off a table before I brought it over the car in case it didnt work! Glass is all now bonded on and left with weights on to push it down. I will check it out when it has set and if necessary add some more underneath, dont want this flying off at speed!

Pic 4, As you may remember, taking advice from other builders, I had my front badge area filled in, as its a little too small to take the replica badges we get of t'interweb, this way, it sits nicely on the bonnet. This then meant that I didnt know exactly where the badge should be, but I know its in the middle of the bonnet, 4cm from the front edge, so I had to do lots of measuring to find the centre using the rear view mirror on the windscreen as a reference point.

Pic 5, I then drilled the holes for the "spikes", these threaded spikes are not long enough to use the nuts on, so I applied some black sticky stuff and the pushed the badge on...cant beleive I didnt get a pic after it was fitted!

Pic 6, onto the side shields, lots of measuring and marking on masking tape until I was happy, then copied it to the other side.

Pic 7, peeled off the back sticky and stuck it on and then removed the masking tape....looks good to me!

continued....
Title: Re: Phils 4thirty build
Post by: Phils99 on January 01, 2015, 07:52:49 PM
I didnt like the big gap behind my bonnet catch so I decided to cover it....

Pic 1, This is the gap I mean, I know its not seen, but it looks ugly...

Pic 2, I found a piece of fibreglass I had trimmed off from somewhere that I cant even remember where from now, but it was the perfect shape for the gap..

Pic 3, I cut a shape out and a slot for the bonnet catch...

Pic 4, ...and then placed it on the top of the bonnet catch bracket, I will now spray this with the textured black paint and then bond it on later

Pic 5, I also masked off and sprayed the bonnet catch and bracket satin black so it looked nicer

Pic 6, As everything else was left drying/setting, I thought I would do a little in the inside, I started by removing the wing mirror adjuster switch, this was easy, it just pushes out, the hazard switch was much harder, I could not see how it comes out as you cant get your head it to look! In the end, I cut a square around the switch to remove the front layer of plastic, I could then see that its just held in place by a tab on the bottom that needs lifting the bit it clips onto is just above my thumb

Pic 7, This is what I was left with, so I dont want the warm/cold air going into the dash....

Pic 8, so I placed strong tape over the hole to cover it, I have also managed to remove all four oblong vents and also the inner part from the outside vents that shuts the vent off using the thumb wheel, dont want these to close after the replica dash has been installed.

Roll on tomorrow...another day in the garage (half day though, as I have to work in the morning!)
Title: Re: Phils 4thirty build
Post by: Furrari on January 01, 2015, 09:40:36 PM
Ref post 715.
This shows the level of detail required for even a little job like fitting a bonnet badge.  This is what makes the difference.
I've spent two weeks looking for "just the right switch" and ended up making my own ( see the prototype on Furrari build - West Coast), again a lot of work for a small thing, but if it's not what you want it's not right, and you know it.

Fantastic detail.
Title: Re: Phils 4thirty build
Post by: Phils99 on January 01, 2015, 10:10:42 PM
Cheers mick! your absolutely right! I'm seeing loads of things I would like to do, but if I do them, I will never get it finished!
Title: Re: Phils 4thirty build
Post by: Phils99 on January 02, 2015, 07:02:55 PM
more done today

Pic 1, rear deck grills bonded into place, lucky I had a big batch of these pens to hold it on with!

Pic 2, Paint now dried on bonnet catch and plate I made, so I have bonded the plate on now. It covers the big gap from the bonnet catch bracket.

Pic 3, here is the pic of the bonnet badge I didnt take yesterday!

Pic 4, I then started on the B piller rubbers, these fit much better if you rumove this "lump" pointed to by the screwdriver

Pic 5, here it is removed

Pic 6, I then fitted it and make sure it lined up ok with the interior plastics and then drilled holed for the "bungs" that hold it on

Pic 7, plastics test fitted with the B piller rubber....just need those Z flap rubbers now!
Title: Re: Phils 4thirty build
Post by: Furrari on January 02, 2015, 07:33:50 PM
Ref post 716
I'm luckey.  The jobs I'm trying to do don't affect using the car because they are all add ons.
Title: Re: Phils 4thirty build
Post by: MADMAN on January 02, 2015, 11:31:49 PM
Phil neat job filling behind the bonnet catch, I may steal that idea ;) but if you change make of car via VOSA then they will need to see the VIN no. may pay to make it removable
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Furrari on January 03, 2015, 10:24:05 AM
Consult the rivnut king.
Title: Re: Phils 4thirty build
Post by: Phils99 on January 04, 2015, 05:42:19 PM
As it was freezing again today, I decided to do a bit of indoor work and get the headlights built up...

Pic 1, Firstly, I had to remove a little bit off one of the side lights lenses as it didnt fit nicely into the slot, wish I had noticed this before I had painted the headlight bodies and I would have made the slot longer...

Pic 2, I dug out my trustee glue gun!

Pic 3, I then glue gunned the side light lenses into place and clamped them until dry, which doesnt take long...

Pic 4, glue now dried on the side light lenses...

Pic 5, so I turned them over and glued in the "switchback" side lights I am installing, these are aces, them glow white for side lights, but then flash amber with the indicator!

Pic 6, I actually got to this position a week ago, the indicator strips were too long, but I didnt dare cut them so I left them hanging out.....BIG mistake, these lights are a very fragile strip of circuit board with leds fitted on, one little bend the wrong way and the strip was broken, I then ordered 2 more of a shorter length which fit perfectly so they dont hang out now...

Pic 7, I then lined the inside of the indicator area with some reflective strip

Pic 8, The side light cover plate was then glued into position

continued....
Title: Re: Phils 4thirty build
Post by: Phils99 on January 04, 2015, 05:57:12 PM
..continued

Pic 1, ...and fitted the indicator lens, I have since noticed that, to make these look right, there is a left and right lens, and, typically, mine are the wrong way round. the lens has moulded "lines" that should run vertical, as I have fittd mine in the wrong lens, they run at 45 degrees, I am going to see if I can get my hand through the headlight hole to change them over as I didnt bond these in as they were a tight fit.

Pic 2, I found that the indicator bulb holders didnt fit in tighte enough and needed another rubber washer adding to make them tighter

Pic 3, they now fit nicely

Pic 4, I then used the "dum dum" seal for the headlight, but I found that this was really thick and, bolting the lens on was putting a strain on the lens, so on the other headlight, I didnt use it

Pic 5, I then taped up the lights to seal them round the lenses

Pic 6, On the car, I used this "D" rubber under the headlights opening in the wing

Pic 7, here you can see the D rubber fitted

Pic 8, I then fitted the headlight and held it in place with some wood and gaffer tape so that I can mess with the brackets, I also attached all the wiring so that I could test them and they both work fine.

Next job will be to bond the headlight body to the metal adjustable plates
Title: Re: Phils 4thirty build
Post by: Phils99 on January 05, 2015, 09:32:40 PM
quick hour in the garage tonight...decided to remove the airbag connections, but, I still wanted the warning light to come on and go off when the ignition is turned on...this is acheived by soldering a resister of value M3R3 across the airbag wires.

I went into Maplins yesterday and just asked for 2 M3R3 resistors...38p in total!

I then cut off the steering wheel airbag plug and put that aside as I will be using this for the push button start later on

Pic 1, I cut the plug off, stripped the wires and pushed on a heat shrink tube..

Pic 2, I then soldered the M3R3 resistor across the 2 wires I then pushed the heat shrink over the resistor and shrunk it down..

Pic 3, as I am fitting the replica dashboard cover, I dont want my passenger airbag going off as it will explode my dash! so I pulled out the plug and also cut this one off and soldered a resistor across it. You cant remove the passenger airbag as the bonnet release lever and the glovebox catch are both mounted on it!

The big test....turned on the ignition...airbag light comes on...then..goes off again!! sweet!
Another little job off the list!
Title: Re: Phils 4thirty build
Post by: Furrari on January 05, 2015, 10:42:26 PM
Phil.  Thanks, that info is valuable to all of us.
Title: Re: Phils 4thirty build
Post by: kalifornia on January 06, 2015, 09:46:56 AM
Good information. Great build.
Title: Re: Phils 4thirty build
Post by: paulcas on January 06, 2015, 03:21:27 PM
keep up the good work Phil - when are you hoping to have her completed by?
Title: Re: Phils 4thirty build
Post by: Phils99 on January 06, 2015, 04:15:07 PM
hey Paul!

I WILL make the shows with her this year!

Mechanically she is almost complete, just the headlights to bond into position and the fake calipers to repaint and fit, oh and the roof to fit :-(

anyway, the list is getting smaller, but still lots of jobs to finish off. I have made this harder for myself with the rear deck release solenoids, fuel flap solenoids and the OEM Ferrari centre console!!...all of these needs load of wiring and fettling to get working.....

I may not get the interior done in time due to lack of finances at the moment (divorces do that to you), but I have the green machine I can steal seats etc out of, so, interior will be my last job and if necessary, Ill come to the shows with the interior still to do!
Title: Re: Phils 4thirty build
Post by: Phils99 on January 13, 2015, 08:11:31 PM
little bit more on the headlights done tonight...

Pic 1, I roughed up the headlight mounting bracket ready for bonding on the headlight

Pic 2, I then jammed the light unit into the hole using wood underneath to hold it in place (you can see a piece of wood to the right), also, it seems that my wing mounting brackets needed lots of washers to make them fit ( you can see this below the wood on the right), I think that the large headlight/wing mounting bracket must be low, as, when I pushed up the headlight mounting bracket to the headlight, it didnt touch. This meant that I had to raise my headlight mounting bracket by placing spacers under it (these can be seen middle of the picture, under the bracket taped together) I then removed the bracket, blobbed on a load of P40 refitted the bracket at the lowest position and then forced it up against the underside of the light housing. I tightened the bolts and left it overnight to dry

Pic 3, When it had dried, I removed the headlight unit  with bracket attached and was going to add more P40 if it needed it, but it is rock solid so thats good! I just sprayed the P40 with satin black to make look a bit nicer (didnt get a pic of this)

Pic 4, Next step was to fit the hella headlight to the end of the bracket, before I did this, I added a load of draft excluder around the edge just to hopefully seal the light against the sides of the headlight housing

I will now do the same on the other side......
Title: Re: Phils 4thirty build
Post by: Phils99 on January 26, 2015, 08:23:19 PM
Ive been a bit quiet of late as I havent been able to get much time in the garage lately due to the weather and other things.....

I did manage to get some time last night and carried out some wiring of the rear deck solenoids and also the fitting of the solenoid switches I am looking to use. I didnt get many pictures of the wiring as its just wires!

Pic 1, I took the original petrol flap/rear deck release levers and removed the lock and also ground off the actual levers, I then cut out a larger hole in the remaining frame....

Pic 2, ...so that the double switch would fit like this

Pic 3, I then fitted the bracket back in place with the switches fitted and I think it fits pretty well, I will spray it black so it cant be seen through the carpet and I will also have to "patch" a hole in the carpet where the levers used to stick through

Pic 4, bracket sprayed black ready to test fit later
Title: Re: Phils 4thirty build
Post by: cheets on January 26, 2015, 10:47:59 PM
Looking good Phil like the switch what is out of i was going to put my switches on the dash
Title: Re: Phils 4thirty build
Post by: Phils99 on January 27, 2015, 08:28:49 AM
cant remember now, I know I just searched ebay for a petrol flap switch, im pretty sure its off a ford....
Title: Re: Phils 4thirty build
Post by: Phils99 on February 09, 2015, 11:10:53 AM
so, the weather was lovely up my way on sunday so I managed to get some time in the garage.

I managed to finish the wiring of the rear deck and fuel flap solenoids and these now work a treat from the push switches I have installed where the levers used to be.

The wiring is pretty straight forward, and for safety I am using the earth through the switches from the handbrake when it is engaged to operate the relays to open the rear deck/fuel flap so that you dont accidently press the buttons whilst driving.

I had to lower the deck latching pin to take a little pressure off the latches as they wouldnt pop initially. I was worried that this would increase the gap between my rear deck and the main body near the roof area, but it is fine so I am a happy bunny!

No pics as it was just a couple of relays and a bundle of wires, I will get some pics when I have mounted the relays and tidied the wiring up.

I have attached below the wiring diagram I created for me to follow for the rear deck/fuel flap release solenoids in case anyone else wants to use it.
I TAKE NO RESPONSIBILITY IF YOU DO THIS AND BLOW YOUR CAR UP...THIS WORKED FOR ME!!
Title: Re: Phils 4thirty build
Post by: Furrari on February 09, 2015, 12:46:57 PM
Phill.  Wow, wireing diagrams.  What next?  I might try that for the sparky bits on The Furrari.

The mainstream manufactures spend millions (Merc spend £1.5M a DAY) on R&D.  All ours is done by men in garages in their spare time. Are we just incredible people or what.
Title: Re: Phils 4thirty build
Post by: Phils99 on February 09, 2015, 01:16:09 PM
cheers Mick,

I always find I have to think about how im gunna wire it up, then scribble it down on paper, then realise I can do it better with less wires, then redo it and then draw it down for my own records, when I tidy it up, I will add the wire colours to this diagram and store it with my car docs, cos when summat goes wrong in 6 months time I wont remember what went where!

...and yes we are all incredible people in our own little way and I for one like to contribute back to this forum any ideas that may help others as I have gleaned so much from the great builders and people on here!

Roll on the kit car shows, its gunna be awesome this year, dont forget people, bring plenty of beers for the saturday...and your foldaway chairs!
Title: Re: Phils 4thirty build
Post by: Furrari on February 09, 2015, 02:00:59 PM
I've just been in my think tank ( the shower, not the loo) and was thinking about your wiring.

In the past I've had comments made on my work which I can accept or reject but the following thoughts came to me.

You have switched the solenoids via the earth line ( yes I knowing do but that's a transistor thing) with one switch.  This means that the coils are live all the time so that if there is a fault to earth after the coils both solenoids will work and open the lid ( I know that you you have fitted manual pulls to open the catches if you have a flat battery)   If you put the switch before the coils a fault would just blow the fuse.  I, me, personally, would at least replace the switch with a double pole, double throw type so that each circuit is separate or preferably two switches.

Hope you don't mind my comments

Mick.
Title: Re: Phils 4thirty build
Post by: Phils99 on February 09, 2015, 02:22:35 PM
absolutely not mick, all comments appreciated!

The switches I have are off, I think, a ford foces and they are a combined fuel flap/boot release switch and are both single pole. This was the best looking combination switch I could find to do the job, so I would like to keep the switch as it is.

The wiring run of the switchable earth is very short, from the front of the seat (where original levers used to be) to the relays in the storage box behind the seat, the wire is fully protected under trim etc so the chances of getting an earth fault on this wire is very slim.

Valid comments non the less and I will take my chance and should I develop a fault in the future, I will look to rewire them.
Title: Re: Phils 4thirty build
Post by: Phils99 on February 17, 2015, 08:15:38 PM
as it was a little warmer this week I had had a few bouts in the garage.

Pic 1, I finished off my mounting of my rear deck/fuel release switches and they fit nicely where the old levers used to be

Pic 2 and 3, I then needed to just finish off my door cards, as they needed to go to the trimmers! I messed about until I could get the door card top edge as low as I could to match the top edge of the outside door, they are not absolutely level, but near enough...

Pic 4, view from outside the car, you can see a little of the doorcard edge on the right but im happy with it.

Pic 5, I then moved onto fitting the front bumper underneath cover

Pic 6, all fitted!

Pic 7 and 8, I had hummed and ah'd about fitting the rear aero kit, as the Hamaan kit doesnt have it on, so I tried it in position, and you know what? I like it! so they are staying!
Title: Re: Phils 4thirty build
Post by: Phils99 on February 17, 2015, 08:20:59 PM
another littlejpob is bonding on my fake door locks, which are actual door locks bonded onto a large washer...

Pic 1, added the black stuff to the large washer

Pic 2, bonded from behind and held in place with a piece of gaffer tape until it dries!

I took my interior in to the trimmers on saturday, so that will probably be ready in 4 weeks or so!..... better get a move on!
Title: Re: Phils 4thirty build
Post by: Phils99 on February 22, 2015, 04:38:44 PM
Today, firstly i checked the bonding of the pods I did the other night before starting on the roof

Pic 1, drivers side pod,stuck nicely

Pic 2, from the front may have to put a short pipe over the end of this as ypou can see light through it!

Pic 3, passenger pod, I attached the pipe to direct the air to the induction kit I had fitted as it just fit inside the hole perfectly!

I then started on the roof, I havent detailed anything here except parts that may be missing from the bible - Paul79 build thread

Pic 4, laid out all the parts to check they are all there and OK

Pic 5, My window hadnt been cut out so I had to do this first

Pic 6, I used a "paddle" I had created to protect the back window as I cut the material

Pic 7, I then cut out the slots where the T pieces come through from the rear deck

Pic 8, I then removed the old roof, which is detailed in Pauls build, but I found that these screws on the front edge were rusty and I needed to use a screw bit in a ratchet to moive them, but they did come off OK
Title: Re: Phils 4thirty build
Post by: MADMAN on February 22, 2015, 04:48:35 PM
The list must be getting shorter now Phil, soon have all the jobs finished
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on February 22, 2015, 05:04:27 PM
I then tested the roof fit on the car and found a problem, at the front edge of the new roof, you should have 2 "corners" stitched in where the front corners of the metal work fit it, I found my new roof had only one corner stitched it, the other side hadn't been done :-(

My brother went in the house and tracked done some strong twine we could use and a strong needle, I then used the stitched corner to mark where the unstitched corner should be stitched, we then stitched it up

Pic 1, my brother stitching the corner in for me, this then fit the front perfectly when done!

Pic 2, I then lined up the rear pod parts and pop riveted the straps in place after working out the gap between the middle and rear bar.

Pic 3, from another angle

Pic 4, we then fitted the inner headlining in place and then used the evostick to stick it to the first bar and hold it in place with the pipe covers.

We decided to leave it there for today so that the glue can fully dry.

Pic 5, QUESTION: what do you do with these flappy bits on the headlining? cant really see exactly where they should be fixed...
Title: Re: Phils 4thirty build
Post by: Paul79 on February 22, 2015, 08:43:16 PM
Phil, re: your question. I'll have a look at my thread and see if I can refresh my memory and I'll let you know
Title: Re: Phils 4thirty build
Post by: Paul79 on February 22, 2015, 08:52:24 PM
.so for the front part of the headlining I glued it on the top of the front rail with the front bit tucked underneath and inside the car with the roof locked off

Title: Re: Phils 4thirty build
Post by: Paul79 on February 22, 2015, 09:12:20 PM
So for the flaps at the front it just trimmed the material to be flush with the mr2 front rail. Seemed to be ok for me.
Title: Re: Phils 4thirty build
Post by: Paul79 on February 22, 2015, 09:22:24 PM
And for the flaps at the rear I think I just pulled the headlining around the rear 2 bars Tight and then glued and trimmed the excess material. The pictures explain it better. I think I even used black gaffer tape aswell to secure further.
Title: Re: Phils 4thirty build
Post by: Lee22 on February 22, 2015, 10:32:41 PM
Hi Phil,

Looking great mate....!

Can't wait to see it finished...  Almost there ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on February 23, 2015, 08:10:52 AM
Cheers Paul, as long as I havent missed an obvious "it goes like this" then I will probably do the same as you.

I think it looks great with a headlining in, the MR2 didnt have one!

Thanks Lee....cant wait to get it on the road myself!
Title: Re: Phils 4thirty build
Post by: ferrari feb 14 on February 23, 2015, 08:25:32 AM
Looking great phill,looks like we will both get our cars to the first  show this year, I hope to get mine down for mot this weekend , cheers jd
Title: Re: Phils 4thirty build
Post by: Phils99 on February 23, 2015, 09:08:07 AM
cheers JD, im hoping to get mine to MOT beginning of April to give me a month to drive it around before driving down to the show.

I think that I will meet up in Pontefract with 3+ other cars, we will then drive down and possibly meet up at M1 jct 30 with a few more, so we could maybe meet you there and then drive 6-7 Ferraris in convoy down to Stoneleigh!
Title: Re: Phils 4thirty build
Post by: Phils99 on February 24, 2015, 10:39:43 AM
so...I never really fancied having the holes cut in the rear bumper to have reversing sensors fitted, so I have been just waiting for another solution to slap me in the face.

I played with the "radar" strip you stick to the inside of the bumper, but I wasnt happy with it...then I have just stumbled onto this!

http://www.ebay.co.uk/itm/Number-Plate-Mount-Reversing-Parking-Rear-Sensor-Three-Sensors-Audio-Buzzer-DIY-/330966536924?pt=LH_DefaultDomain_3&hash=item4d0f2492dc (http://www.ebay.co.uk/itm/Number-Plate-Mount-Reversing-Parking-Rear-Sensor-Three-Sensors-Audio-Buzzer-DIY-/330966536924?pt=LH_DefaultDomain_3&hash=item4d0f2492dc)

This looks perfect! its 3 sensors built into the lower part of the rear number plate, now, as I already have my number plate configured to lift up to access the trickle charger/emergency rear deck/petrol flap release cables, this will be easy to fit!

I have ordered it and will let you know how good it is when I fit it (more work!!)
Title: Re: Phils 4thirty build
Post by: Furrari on February 24, 2015, 10:54:06 AM
Phill.
There is a potential problem with the West Coast that the splitter is lower than the front of the SL.  Although you can ( and I do) lift the front of the car quite a bit ( just press a button) to drive around in speed hump areas it does settle a bit when the engine is off.  This means that you can park with the splitter over a curb and have it damaged as the car settles.  The Parkatronic sensors in the bumper are too high to assist in preventing this.

I have looked at mounting a set of sensors in the splitter but haven't done anything yet as I waiting to see what the Aero kit is like.  This bit of kit looks as though it might do the job in picking up the curb and it's range can be adjusted by altering the angle of the plate mounting.

I will watch developments with interest.

Mick
Title: Re: Phils 4thirty build
Post by: Phils99 on February 24, 2015, 11:04:02 AM
yea...watch my posts, ill keep you updated....
Title: Re: Phils 4thirty build
Post by: Wizard on February 24, 2015, 12:39:11 PM
Phil, seems like a good find, should do the job well.
Title: Re: Phils 4thirty build
Post by: Furrari on February 24, 2015, 01:16:05 PM
Another problem with the Parkatronic is that on The Furrari the outboard sensors are further round than on the SL so they pick up walls and things that are at the side when they are still a fair distance away.
Come the good weather another of my jobs is to reduce the sensitivity of the sensors. (Anybody any ideas?)
Adjustable (industrial style ) sensors are available but I've never used them and they look a bit bulky and I have no idea how they would interface with the existing system.
I suppose I could get one and see.
Title: Re: Phils 4thirty build
Post by: johnjames on February 24, 2015, 02:15:32 PM
Hi Phill the car is looking great.
                                         
                                           Like the idea of the number plate with the sensors, when I fitted the number plate to my white 430 I held it about 2

feet from my gas hot plate so it got a little bit soft had to wooden blocks each end and a heavy weight in the middle when it called down it was

the right shape to fit the front bumper wondering if you could do this with the  new number plate bracket that way you would have parking

sensors on the front you take care buddy see you at Stoneleigh
Title: Re: Phils 4thirty build
Post by: Phils99 on February 24, 2015, 02:50:18 PM
JJ, hmm interesting idea!

I will have a look at it when it comes to see if that is possible, to be honest, the front is not usually the issue as you can see it, its the back you cant see....
Title: Re: Phils 4thirty build
Post by: Lee22 on February 24, 2015, 09:52:19 PM
Just be careful buying these parking sensors in number plate surrounds.

I paid good money for one for the back or the Mrs. Car.....

They worked for less than 1 month, then went faulty...

I was send a replacement, and I fitted that on.... Less then 2 weeks later, same problem.

So returned it and got money back...

When I googled them (afterwards), it seemed like this is a common fault.

So just be careful..

Lee
Title: Re: Phils 4thirty build
Post by: Phils99 on February 25, 2015, 08:26:50 AM
cheers for that Lee, hopefully it will be OK, at least its an easy fit and removal if it does go wrong.
Title: Re: Phils 4thirty build
Post by: Phils99 on March 01, 2015, 06:29:09 PM
so, more roof work today

Pic 1. I trimmed off the excess material at the front and glued it under

Pic 2. I also trimmed off the rear part and glued it around the 3rd bar to keepit straight when roof is up

Pic 3. The inner liner sits nicely along the edge now

Pic 4, I drilled out the holes in the brackets that secure the wires to the roof skin so that I could use nice big rivets

Pic 5, 6 and 7 I then attached the side wires bracket to the part of the roof that is marked using the large rivets
Title: Re: Phils 4thirty build
Post by: Phils99 on March 01, 2015, 06:41:46 PM
Pic 1, I then started on the part where the wire is glued into the fold, this is the chalk mark from when the roof was in place, I then added a lower marked which is where I will glue the wire into

Pic 2, this shows the wire glued in, as this is contact adhesive, it sticks instantly so that I could try it against the car

Pic 3, here it is on the car! fits nicely so that the wire pulls the roof into the channel in the frame when the roof closes.

Pic 4 and 5, I then  added all the metal parts removed earlier and also the rubber seal, I then closed the windows and made sure that they pushed into the rubbers to form a deal, the passenger window needed somw adjustment to fit correctly.

Pic 6, I then had a play with my reversing beepers number plate, it worked fine on the chair moving it towards things, so im gunna fit it

Pic 7, as I have the lift up number option at the rear, I firstly fitted the hinges to the reverse beeper number plate, I will fit this to the rear of the car next time

Pic 8, I then forced the front number plate into a curve and applied some heat with a heat gun, hopefully this will stay curved so that I can fit it tpo the front of the car
Title: Re: Phils 4thirty build
Post by: Phils99 on March 01, 2015, 06:44:26 PM
and just a couple of pics with the roof up and windows closed...
Title: Re: Phils 4thirty build
Post by: Paul79 on March 01, 2015, 07:02:37 PM
well done on the roof matey. there you go, it wasn't that bad eh?  ;)
Title: Re: Phils 4thirty build
Post by: Wizard on March 01, 2015, 07:03:49 PM
Phil, fantastic achievement. Well done, make the car look 99% complete now.
Title: Re: Phils 4thirty build
Post by: Lee22 on March 02, 2015, 12:37:06 AM
Looking proper smart now phil....!

Well done mate
Title: Re: Phils 4thirty build
Post by: Phils99 on March 02, 2015, 08:25:10 AM
Cheers guys..

Paul, it was much easier with your write up and the DNA one you sent me, thanks for that.

Wizard/Lee, yet the car looks totally different with the roof fitted!

I also popped into the upholsterers on Saturday and he has done the dashboard and it looks amazing!

He has done 1 door card also, but he hasnt done the armrest as I wanted so I will need to get him to redo that, but its only a small part....he is gunna do the seats this week...

I need to get the sound system sorted now, then I can reassembly the rear boxes, as that is where I plan to mount the sub amp.
Title: Re: Phils 4thirty build
Post by: kalifornia on March 02, 2015, 09:53:41 AM
You make the roof fitting easy lol, but I know its very hard and tricky.
Well done for a job that most people shy away from. Car looks amazing.
Title: Re: Phils 4thirty build
Post by: Furrari on March 02, 2015, 12:21:37 PM
May the sun always shine on you.  May you never need to use the roof.  :-)
Title: Re: Phils 4thirty build
Post by: Phils99 on March 02, 2015, 12:33:53 PM
cheers Kal, I was gunna get someone to do the roof, but, it that old Top Gear saying "How hard can it be?" and to be honest, it wasnt that hard.
The DNA roof is WAY less complicated than the MR2 roof and you get an inner lining which looks lovely from inside the car.

Its all really common sense and I would think it could be figured out by the average man in the street, the secret is knowing what parts from the original roof you DONT need, such as the spring bit that connects across the middle of the MR2 roof etc.

I also, like Paul, didnt use the foam round the bars as it seemed to make the roof too big to fold into the foldaway opening, this meant it stuck up a bit, which meant the fake engine never sat on the MR2 body, but rested on the roof, which then meant I had to use excess force on the rear deck to latch it, which then meant that the release solenoids woulnt work as the catches were under too much pressure!

I think it looks fine without the foam tubes and sits nicer in the foldaway opening.

Cheers Mick, I do not have any intentions of taking it out in the rain, although, knowing the british weather, I am sure to get caught one day....
Title: Re: Phils 4thirty build
Post by: ferrari feb 14 on March 02, 2015, 12:43:14 PM
Looks well smart phill ,not long now  I bet you can't wait ,jd
Title: Re: Phils 4thirty build
Post by: Phils99 on March 02, 2015, 09:31:09 PM
managed a couple of hours tonight...

Pic 1, attached the front number plate with sticky pads

Pic 2, I then mounted the rear numberplate/reverse sensors unit on hinges so it lifts up when needed

Pic 3, and checked it out with the side lights on

Pic 4, I then started the wiring up, I will mount the unit here and the beeper behind the rear storage boxes

Title: Re: Phils 4thirty build
Post by: Lee22 on March 02, 2015, 10:28:05 PM
No private number plate phil?
Title: Re: Phils 4thirty build
Post by: Phils99 on March 02, 2015, 10:45:28 PM
Not yet....
1. not seen anything I like, and
2. run out of cash!
Title: Re: Phils 4thirty build
Post by: rudycob1 on March 02, 2015, 11:00:15 PM
Looking great. This is defo going to turn some heads. :)
Title: Re: Phils 4thirty build
Post by: Wizard on March 03, 2015, 08:10:51 AM
Phil, what you doing for your sound system. I'm going for a JL Audio jx250 mono amp, JL CP1 ported sub to compliment my new doorcard speakers.

I don't need it to be loud, but nice and clean bass.
Title: Re: Phils 4thirty build
Post by: Phils99 on March 03, 2015, 08:26:22 AM
I have the underdash sub box from the MR2ROC forum, and this will take a JL sub and I also have uprated door speakers but cant remember which ones they are now!

I love subs now, having never had one in a car before, I bought a Boxster with the Bose sound system and a lovely sub...its amazing!
Title: Re: Phils 4thirty build
Post by: Furrari on March 03, 2015, 08:56:37 AM
I used an audio unit that included a reversing camera on The Furrari.  It gives great peace of mind when reversing.
Title: Re: Phils 4thirty build
Post by: kalifornia on March 03, 2015, 09:02:42 AM
I had a complete new sound system fitted. Even though the previous one was a bose, it didn't have that kick to it. Loving it. I went with a top of the range Kenwood with Sat Nav, Hands free, etc... and new speakers and amp. Don't want to think about the price, I might start crying again.lol

I also had room for a big twin bass woofer box on the back seats/luggage area.

When the Sun is out, roof down, some nice music with a kick, it's like being in heaven, I can find a excuse to stay out all day. lol

Title: Re: Phils 4thirty build
Post by: beemaman on March 03, 2015, 11:16:14 AM
cant beat a stereo upgrade in these cars so sound and looks together :)

ive fitted jvc mp3/bluetooth etc etc stereo and jl audio component speakers front and rear and 2 x under seat subs and amps and it sonds pretty good so im happy for the upgrade and i can remotely turn bass boxs up and down and have fitted a on off switch for the subs if not needed at ay point.

id reccomend a stereo pgrade to anyone who has one of these cars.just finishs it off nicely :)
Title: Re: Phils 4thirty build
Post by: Phils99 on March 03, 2015, 12:19:02 PM
I will detail mine when I get round to fitting it!

As a question, I dont want to loose space in my rear boxes.....has anyone fitted an amp behind the passenger seat just below the rear box? I have a slim amp that I think would fit, but not sure if the seat will hit it when fully back?
Title: Re: Phils 4thirty build
Post by: kalifornia on March 05, 2015, 10:46:43 AM
When I had the 360, I ended up screwing the amp to the actual storage bin lid. I placed two small boxed speakers in the bins.
Title: Re: Phils 4thirty build
Post by: Phils99 on March 05, 2015, 12:06:42 PM
cheers Kal, Ill have a play with my green machine doner vehicle as my seats are at the trimmers..
Title: Re: Phils 4thirty build
Post by: Wizard on March 05, 2015, 06:56:48 PM
Phil. Both my sub and amp will go in the my rear storage bins as they won't fit anywhere else. I did try to get the underdash mounted sub but couldnt get hold of one. Will be interesting to hear how it sounds. They got good reviews.
Title: Re: Phils 4thirty build
Post by: Phils99 on March 05, 2015, 09:50:26 PM
got another couple of hours in tonight...concentrated on finishing the reversing beeper number plate holder and the straps to secure the rear window in the hood.

Pic 1, as the wire on the reversing beepers is not long enough to get to the rear storage boxes, I decided to mount it here, I will be adding D rubber along the edge of my rear deck, so water shouldnt get at it. I must say, Im impressed with them, as I tested by moving a board nearer to the back of the car and they work just like factory fitted ones....lets see how long they last!

Pic 2, Whilst I was in the area, I connected the nice straps I salvaged from the roof strip down to my fake engine to replace the old bit of string I had temporarily used.

Pic 3, I then trial fitted the rear storage bins, as I remembered mine had luggage securing straps fitted. I removed the loose strap end and the secured end with the buckle was at the front...result! it was directly underneath where I had the strap from the rear window plate coming through. I was always intending to secure the rear window plate inside the box so that I still had access and this strap will be secured just behind the door meaning that I still have full use of the doors and the storage area. I had to trim about 5mm off the width of the rear window securing straps, as the buckles are narrower..this is the end of the long strap whilst the window wasnt in position...

Pic 4, Roof correctly fitted and rear window plate in place, I trimmed all the way up the strap so I can leave it connected when the roof is folded away, I may shorten this when I start to use it, and then used the MR2 buckle to pull it tight....works a treat! much better than the supplied press stud!

Pic 5, from a different angle, I need to thread the strap behind the large bar where the storage box door catch is welded on so that it ends up level with the door and allows it to close, other than that, I m pleased with the fit! I can now start assembly of the rear storage bins as the only other wiring left will be down the centre console which I can leave uncovered until I get it all done.


Title: Re: Phils 4thirty build
Post by: Phils99 on March 06, 2015, 08:25:59 AM
I know I keep adding things to my list, but I like the look of this!

Anyone got/tried one?

for the price its got to be worth a look?

http://www.ebay.co.uk/itm/LED-Car-HUD-Head-Up-Display-OBD-II-2-Speeding-Warning-System-Fuel-Consumption-/111593335787?pt=LH_DefaultDomain_3&hash=item19fb7b2beb (http://www.ebay.co.uk/itm/LED-Car-HUD-Head-Up-Display-OBD-II-2-Speeding-Warning-System-Fuel-Consumption-/111593335787?pt=LH_DefaultDomain_3&hash=item19fb7b2beb)
Title: Re: Phils 4thirty build
Post by: Furrari on March 06, 2015, 09:03:28 AM
Phill.  Check the reviews on these.  Generically they don't receive very good reviews.  I live in hope that this is a good one, especially if you are trying it.  I wonder if they do one that shows revs?  A HUD would be very Furrari.
Title: Re: Phils 4thirty build
Post by: Phils99 on March 06, 2015, 09:17:24 AM
yea...im just thinking for 20 quid, it may be worth a punt.......

They all show revs dont they? thats the curve of leds in the display...they also can alert to change gear when revs are too high!
Title: Re: Phils 4thirty build
Post by: Phils99 on March 06, 2015, 09:35:07 AM
ok, took a chance on this one as its UK based and I can easily send it back if its pants:

http://www.ebay.co.uk/itm/161300597728?_trksid=p2059210.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT (http://www.ebay.co.uk/itm/161300597728?_trksid=p2059210.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT)

I also has £15 worth of Nectar points I had transferred to ebay, so it only cost me £15 in the end!

Ill let you all know if its any good as i can try in in my Porsche before hand
Title: Re: Phils 4thirty build
Post by: Phils99 on March 06, 2015, 12:10:31 PM
...also as an update, when I bought my car, DNA could no longer get the f430 replica wheels and I didnt like the wheels that they were supplying in the kit...Brian then said that he had a set of secondhand different wheels in the "loft", I checked them out and they were the same as Madmans wheels, which I loved, so I snapped them up and we negotiated a discount on the price of the kit as these were second hand and had part worn tires on.
After a couple of months I then noticed that one of the tyres was actually damaged and would not pass an MOT, so I started looking for a replacement set....couldnt believe my luck, I found a company in Germany that would supply 2 NEW exactly the same tyres (265/30/19) for £135!!

Order placed!!

...and then, I mentioned it to my brother who works at York college and he said he can get them fitted by the college for free!!

Well pleased!
Title: Re: Phils 4thirty build
Post by: MADMAN on March 06, 2015, 10:26:51 PM
...also as an update, when I bought my car, DNA could no longer get the f430 replica wheels and I didnt like the wheels that they were supplying in the kit...Brian then said that he had a set of secondhand different wheels in the "loft", I checked them out and they were the same as Madmans wheels, which I loved, so I snapped them up and we negotiated a discount on the price of the kit as these were second hand and had part worn tires on.
After a couple of months I then noticed that one of the tyres was actually damaged and would not pass an MOT, so I started looking for a replacement set....couldnt believe my luck, I found a company in Germany that would supply 2 NEW exactly the same tyres (265/30/19) for £135!!

Order placed!!

...and then, I mentioned it to my brother who works at York college and he said he can get them fitted by the college for free!!

Well pleased!
Just looked in Aladdins cave Phil and guess what I have found ;D Ahh they are the wrong size, I have a pair of 215/35/19
close but not close enough ;D
MADMAN ;) ;)
Title: Re: Phils 4thirty build
Post by: Phils99 on March 07, 2015, 12:11:09 PM
Haha! I should have rung steve 'kwikfit' madmans garage first!!
Title: Re: Phils 4thirty build
Post by: Phils99 on March 10, 2015, 09:36:29 PM
ok, so i have spent the last 2 nights in the garage working on the interior.

I started by lining the glove box and then fitted the speakers.

Pic 1, started with the glove box disassembled

Pic 2, I then lined the bottom with the speaker covering I have

Pic 3, then the sides and its all done...easy but real nice!

Pic 4, So next its onto the replacement speakers for the doors, after researching on MR2ROC, I chose these as a direct replacement so didnt need another amp..

Pic 5 and 6, I decided to fit the large speakers into the existing speakers mounting, this is done by removing the original speaker and cutting all the plastic away that holds the speaker in and also removing the old cone

Pic 7, I then drilled out the bonded in speaker plug as I wont be using it

Pic 8, I then ran the speaker wire through the hole to the speaker

Title: Re: Phils 4thirty build
Post by: Phils99 on March 10, 2015, 09:44:54 PM
Pic 1, so the finished  speaker looks like this, not sure if I need to make iot lower, but I cant tell until I get the door cards back to trial fit them with the speaker in. The tweeters should just fit into the hole I drilled in the door cards nicely!

Pic 2, present from Germany arrived today! my new rear tyres, My brother will take them into work on Friday to get them fitted and balanced for free!

Pic 3, next I started working on the under dash sub I bought off MR2ROC ages ago....Im not detailing the install here, as a couple of docs are available detailing this, I will just summerise the install. This is the area under the dash where it will fit.

Pic 4, and here is the UD sud box and the JL recomended speaker I bought.

Pic 5, I removed the speaker terminal part and soldered on connectors to connect to the speaker internally

Pic 6, Like this....

Pic 7, you then mount this unit you removed form under the dash onto the sub box

Title: Re: Phils 4thirty build
Post by: kalifornia on March 11, 2015, 08:43:34 AM
Looking good.
Title: Re: Phils 4thirty build
Post by: Phils99 on March 11, 2015, 05:57:37 PM
couldnt post this last night as the site went funny!!

Pic 1, after a bit of bending and twisting of the supplied brackets. I managed to get it to fit nicely, this is what it looks like from underneath

Pic 2, and this is what it looks like looking from further out

I now have to wire this to the sub amp I have, as this speaker is not powered and will require much more to drive it than the head unit I have can supply..
Title: Re: Phils 4thirty build
Post by: Wizard on March 11, 2015, 07:14:46 PM
Phil, will be interesting to hear what you think of the underdash sub sound quality. They meant to be very good.
Title: Re: Phils 4thirty build
Post by: cheets on March 11, 2015, 10:00:59 PM
looks good Phil do you have the dimensions of the sub box ?
Title: Re: Phils 4thirty build
Post by: Phils99 on March 12, 2015, 08:04:47 AM
cheets, should have asked me that before I fitted it :-(
Title: Re: Phils 4thirty build
Post by: kalifornia on March 12, 2015, 09:16:18 AM
I did the same to my old 360, I bought the underdash box from ebay and bought the sub speaker new.
 Its not ideal in terms of bass quality compared to normal size subs, but for the mr2 mk3 its the only reasonable option, other then spending mega bucks to get a custom glass fibred redesign of the luggage compartment area, as some of the mr2 boys do on their forums.

Your car is coming leaps and bounds, not too long now
Title: Re: Phils 4thirty build
Post by: Phils99 on March 12, 2015, 02:47:21 PM
cheers Kal,

Yea, its a "poor mans" sub, but I didnt want to loose the rear storage boxes....
Title: Re: Phils 4thirty build
Post by: Phils99 on March 12, 2015, 08:40:24 PM
OK, so I loosely ran all the wires from the head unit/power to this old amp I have, connected it all up to power the sub...and....nothing :-(

I think the amp is no good.....I have been on ebay and ordered one to replace it so I will have to wait for this to come before I can test the sub....

Meanwhile, I received a little pressy from my new best mate Beemaman!

He even moved the fake brake pipes from one end to the other on 2 of the calipers, as on closer inspection, the 430 always has the brake pipe at the bottom of the caliper and the Ferrari script ends up being the other way on two of them as well! what attention to detail!

You have to see these for real, honestly, they look like they are solid metal real calipers! Cheers buddy!
Title: Re: Phils 4thirty build
Post by: Wizard on March 12, 2015, 08:53:45 PM
Wayne strikes again. Fantastic work. (As always).
Title: Re: Phils 4thirty build
Post by: cheets on March 12, 2015, 09:22:53 PM
that is ok i did not think but is not to dad at the mow as i have dash out so wen i get back will have a look at what i can get in :)
Title: Re: Phils 4thirty build
Post by: Lee22 on March 12, 2015, 10:41:02 PM
Yep, they certainly do look good..
Wayne re-painted mine too, as they were white when Wayne first did the car...

Look amazing now...

Title: Re: Phils 4thirty build
Post by: beemaman on March 13, 2015, 07:53:14 PM
Your welcome phil glad there what your looking for :) I was impressed myself I must be getting too much practice on these calipers now after yours and lees :) oh and I have Barry's to do yet too lol:) :)

The sub box looks great buddy :) can't beat extra bass :)
Title: Re: Phils 4thirty build
Post by: Paul79 on March 13, 2015, 09:25:52 PM
I'm all about the bass, about the bass, no treble.  ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on March 16, 2015, 09:22:56 PM
the new amp arrived today, so I fitted it in the car and wired up the under dash sub, and I have to say.....Im VERY impressed with the performanceof it!

It works brilliantly hidden away under the dash so it takes up no room in the car, well pleased with it!

One thing I do need is the plastic surround for the stereo, the one I have seems to be smaller and wont fit over the front of my standard double din stereo. Mine is the pre facelift so I am assuming the post face lift had a different surround but I am hoping it will fit the pre face lift.....so if anyone has one kicking about!
Title: Re: Phils 4thirty build
Post by: Wizard on March 17, 2015, 07:46:17 AM
Phil. Glad the the new amp works and the bass sounds good.

Quick few questions, where did you put the amp, and did you install some sort of external bass control or is still all going to be done via the stereo?
Title: Re: Phils 4thirty build
Post by: Phils99 on March 17, 2015, 08:14:35 AM
Hi wizard,
I installed the amp behind the passenger seat and I will velcro it to the carpet below thestorage box. It is very slim so fits there nicely, it is also black so cant really be seen, I will take pics of it tonight.

Yes, the bass controls from the stereo still control the speakers, but I have set it so the bass from the stereo is set to mid way, and boosted the output (gain) from the amp to give the bass level I want. This way the door speakers are not "over driven" with bass, as they started to distort if you fed them too much bass. The crossovers in the doors are only mid/bass and tweeters, if it had mid and tweeters, that would have been better.

If I could be bothered, I would run speaker wires from the amp into the doors and power the Focals from those, that way I can filter the bass out the input to the doors, but, to be honest Im not sure its worth it as it sounds fine as it is....maybe one of those jobs to do at a later date...

MOT is booked for 11th April, got to get cracking now! Not sure I will have the interior finished by then, so I may just pop the centre console and heater surround in from my green machine....

Question: Is a hazard warning switch part of on MOT?
Title: Re: Phils 4thirty build
Post by: tenpin on March 17, 2015, 09:02:19 AM
RE: Hazard light switch
Yes it is, well, they always check it when my car has an MOT.

 - tenpin
Title: Re: Phils 4thirty build
Post by: Phils99 on March 18, 2015, 04:03:17 PM
update for the stereo surround...

Pic 1, this is the one I have, but it doesnt fit round my stereo (this is a pic from MR2ROC)

Pic 2, this is what I want as I think this will fit my stereo ( I have the side pieces already)...anybody have one?
Title: Re: Phils 4thirty build
Post by: MADMAN on March 18, 2015, 04:23:49 PM
update for the stereo surround...

Pic 1, this is the one I have, but it doesnt fit round my stereo (this is a pic from MR2ROC)

Pic 2, this is what I want as I think this will fit my stereo ( I have the side pieces already)...anybody have one?
Aghhh Phil, I found one in Aladdins cave and let Mulaz on mr2 roc have it, thats the one you have a pic of, you could of had that one ::)
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Paul79 on March 18, 2015, 06:51:44 PM
Phil. I got the side pieces like you and I found the surround from the original mr2 radio worked. Although I'm not sure. I can't remember now. Check my thread out.
Title: Re: Phils 4thirty build
Post by: Phils99 on March 18, 2015, 07:56:32 PM
yea Paul, thats the second pic I showed...mine is the first one and doesnt fit
Title: Re: Phils 4thirty build
Post by: Phils99 on March 19, 2015, 08:20:24 PM
managed an hour in garage tonight...


Pic 1, here is my amp mounted behind the passenger seat with velcro...

Pic 2, I then started work on mounting the fake calipers, like Paul, I added some shrink tube to the screw threads to protect them a little from the elements

Pic 3, I then mounted up the fake disc and the fake caliper using the mounting bracket. You have to just keep altering the nuts until it doesnt touch the disc.....I have also completed the fitting of the rear wheel arch liner on this side
Title: Re: Phils 4thirty build
Post by: beemaman on March 20, 2015, 06:54:22 AM
Them calipers look great phil :) not long now til its virtually finished buddy :) keep them coming phill .)
Title: Re: Phils 4thirty build
Post by: Paul79 on March 27, 2015, 06:56:01 PM
Come on Phil. It's been over a week since your last update! Stop slacking.  :)
Title: Re: Phils 4thirty build
Post by: Phils99 on March 29, 2015, 11:37:54 AM
been busy this week, but ive done some little bits and hope to do a little toiday, ill hopefully post tonight...
Title: Re: Phils 4thirty build
Post by: Phils99 on March 31, 2015, 08:15:13 PM
not had much time on her recently due to family and nights out!!

Anyway, I pulled her out of the garage the other day to give her a bit of fresh air as she has been stuck in the garage for months!

here are a few pics of her sunbathing!!

Title: Re: Phils 4thirty build
Post by: Wizard on March 31, 2015, 08:22:42 PM
She looks stunning. What you got left to do, just the interior??
Title: Re: Phils 4thirty build
Post by: Phils99 on March 31, 2015, 08:28:00 PM
started doing a bit of wiring on the steering wheel as I intend to have
1. starter button
2. ferrari horn button
3. manetino switch which lights up the LEDS when the ignition is turned on.

Pic 1 and 2, my first problem is that my car is the SMT and has buttons on the steering wheel to change the gears with, this means that the steering wheel cowl supplied doesnt fit correctly and needs some work to make it fit right

Pic 3, after a little bit of shaping, it now nearly fits....and yes, I did smash my button getting the steering wheel off! I have supergluied this together at the moment but I will replace them when I find some!

Pic 4, I then fitted the start button and the manetino switch, this switch is off a F430 gaming wheel and is metal and give a nice click as you turn it.

Pic 5 and 6, I have also wired up the leds to work when you turn on the ignition here they are off, then on!
Title: Re: Phils 4thirty build
Post by: Phils99 on March 31, 2015, 08:30:49 PM
thanks Wizard, yes the main piece of work is now interior, just waiting for the upholsterer, I need it for next weekend really as I am planning a four day marathon to get her ready for the MOT on the 11th April!
Title: Re: Phils 4thirty build
Post by: Lee22 on March 31, 2015, 10:22:07 PM
Wow Phil.....

Looks great in the sun mate... Well done...

Can't wait to see her in the flesh ;D

Lee
Title: Re: Phils 4thirty build
Post by: cheets on March 31, 2015, 11:10:46 PM
Looks Good Phil

Think i mite have one of the SMT butene will have a look tomorrow for you
Title: Re: Phils 4thirty build
Post by: Phils99 on April 01, 2015, 07:54:45 AM
cheers cheets, that would be great!!
Title: Re: Phils 4thirty build
Post by: ferrari feb 14 on April 01, 2015, 12:38:32 PM
Looks great phill you must be chuffed, now the big push for  mot then stoneleigh 😀 jd
Title: Re: Phils 4thirty build
Post by: Phils99 on April 01, 2015, 08:24:15 PM
yea JD, but not as chuffed as you are with your new MOT!!, well done mate.

had a quick hour tonight

Pic 1, got these in the post today!, the outside diameter is correct, but they dont hold in...may need to bond these on, but dont they need to come off if you have the wheels balanced?

Pic 2, As the new steering wheel surround looks different to the MR2 steering column surrounds, I have sprayed mine with the textured paint to make them look better

Pic 3, I then connected the old airbag plug to my steering wheel cover so I can use this to make the cover easily removable!
Title: Re: Phils 4thirty build
Post by: Paul79 on April 01, 2015, 08:31:08 PM
Like the idea on the textured paint on steering wheel rear cover. I'll nick that idea of you don't mind. 😄
Title: Re: Phils 4thirty build
Post by: Phils99 on April 01, 2015, 08:42:11 PM
steal away buddy thats what this forum is for!
Title: Re: Phils 4thirty build
Post by: cheets on April 01, 2015, 10:24:27 PM
Phil i have one of the switches you need can you PM me your address :)
Title: Re: Phils 4thirty build
Post by: tenpin on April 01, 2015, 11:05:28 PM
.....
Pic 1, got these in the post today!, the outside diameter is correct, but they dont hold in...may need to bond these on, but dont they need to come off if you have the wheels balanced?
.....

Yes, they do need to be removed when they balance the wheels.

 - tenpin
Title: Re: Phils 4thirty build
Post by: kalifornia on April 01, 2015, 11:23:11 PM
That car is looking fantastic. A tribute to it's owner
Title: Re: Phils 4thirty build
Post by: Phils99 on April 10, 2015, 04:26:15 PM
Guys,

As some post have gone missing...some of you will probably remembre that I have broken both my mirrors, ordered new "430" mirrors off ebay and then found that they are too big.

I have spoken to DNA and yes, the mirrors are specially made for our cars, so if you guys break them, you need to contact DNA for replacements.

to get through my MOT, as I have run out of time to get replacements from DNA, I have bought some mirror glass plates and a glass cutter and I am going to fabricate a rough mirror shape to fill the wing mirror and stick those on, hopefully that will do the trick! I will take pis as I do this tonight....I have a long night ahead of me as I have the following jobs:

1. Fabricate wing mirrors and stick on
2. got to timmers and get the steering wheel centre piece and fit this
3. get from trimmers the seat belt clips as they are different ones on my green machine that the ones on my 430, even though they are both PFL!

Title: Re: Phils 4thirty build
Post by: cheets on April 10, 2015, 05:44:28 PM
Hi Phil i am shore you will get it dun :)

I have all ready olted my mirrors to take a 430 glass as i wanted the heated mirrors with wide angel :)

yes have sent switch to day as well have you got sorted from DNA for some new glass as i will have some can get them in the post on monday if you need ?
Title: Re: Phils 4thirty build
Post by: Phils99 on April 10, 2015, 10:26:42 PM
cheers for the present cheets!

yea, brian will sort my mirrors on monday, but see my next post as I have altered the real 430 onwes to fit!
Title: Re: Phils 4thirty build
Post by: Phils99 on April 10, 2015, 10:45:50 PM
Right, I have been working  all last weekend and everynight this week to get the car ready for the MOT tomorrow so I havent had time to post, but I will now!

Pic 1, I originally wanted to use the original speaker mounts for the speakers, but, when door card fitted, they pushed against it as they stuck out too much, make sure you try your speakers with the door cards when trial fitting as I didnt, so had loads of work making them fit.

Pic 2, like others on here I eventually decided to make a wooden speaker mount using the original one as a template, this then mounted the speaker further away from the door card

Pic 3, I had already cut out the original MR2 speaker grill from the MR2 doorcards...

Pic 4 and 5, I then bonded these to the inside of the door card, which I think look much nicer when done

Pic 6, I then reconnected the speakers and tested them before mounting the door card

Pic 7, I then mounted the door card, look earlier in my build thread for how it was mounted, but it was the same way Paul did his by having a bracket mounted to the door which pokes through under the door opener which is then bolted to it making a strong mounted door card. A big tipI have found for getting the door cards correct, is to hang them on the door and then close the door and centre the doorcard in the door opening, as look at from the other side of the car. Mark this position and then bolt the card to the door, this way, the door card wont catch on the door opening plastics like my did originally until I repositioned them, now they are in the right place.





Title: Re: Phils 4thirty build
Post by: Phils99 on April 10, 2015, 11:01:34 PM
So, I decided to buy the new battery and went on a 30 mile round trip to halfords last night after work to get it. I then set about fitting it to the car tonight, and, just my luck, the battery has thinner terminal posts on it with adapters, and the +ve post adapter was missing  :( this then meant another 30 mile round trip tonight to go get one....just what I needed with all the work I have to do! Ive already been to the trimmers after work to pick up the steering wheel centre as he forgot to give me it last weekend....so..

Pic 1, picture of the battery showing -ve post with adapter fitted (left side) and the +ve post missing (right side)

I then started the wing mirror modification...

Pic 2, here is the broken original mirror over top of a real 430 (pattern) mirror, you can see the difference in size....

Pic 3, I then scribed round the broken one and nibbled away the edge on the real 430 one, this turned out ok actually!

Pic 4, I then removed the black plastic from the mirror motor and using a grinder with a sanding wheel, made it flat

Pic 5, this then allows the back of the mirror to stick well to the flat plastic using the sticky pad on the back of the mirror

Pic 6, next was the steering wheel centre, firstly, I lined up the centre and marked the holes in the brackets I had previously bonded to the centre piece onto the plate, I then drilled these holes and inserted a small rivnut

Pic 7, I then mounted the plate using bolts into the rivnuts

Pic 8, and then fitted the horn button! steering wheel completed!!

Thats it then! the car is all ready to go to MOT tomorrow, fingers crossed she passes and we are off, well, I still have the interior to finish, but no rush for that!



Title: Re: Phils 4thirty build
Post by: Wizard on April 11, 2015, 06:39:20 AM
Best of luck with the MOT today
Title: Re: Phils 4thirty build
Post by: Phils99 on April 11, 2015, 07:56:03 AM
I have to laugh sometimes at how unlucky I am.....car in at kwikfit for 08:30....weather forecast? rain between 8 and 9!!....and it's now pi$%ing down....grrrrrrrrrrr
Title: Re: Phils 4thirty build
Post by: ferrari feb 14 on April 11, 2015, 09:17:42 AM
Wow man on a mission,hope she passes her mot phill ,jd
Title: Re: Phils 4thirty build
Post by: Commando on April 11, 2015, 11:34:00 AM
Yes, Good luck buddy.
Title: Re: Phils 4thirty build
Post by: Phils99 on April 11, 2015, 11:36:30 AM
FAILED!!!!!

On:

1. Emission, it read 0.5 instead of max of 0.3, they recon a good run round the block would probably warm it up and get it passed, so they will do that at the retest
2. Excessive play in the front bush on the wishbone! this was a new supplied DNA part??? dont get it, I will need to get it stripped down to see what is going on....
Title: Re: Phils 4thirty build
Post by: Wizard on April 11, 2015, 11:58:27 AM

Bushes....did they let u go under the ramp to have a look at it? May be worth sending Lee a message as he recently brought some wishbone bushes and know the exact part number as the not standard parts. (Think they off a Rover).
Title: Re: Phils 4thirty build
Post by: Phils99 on April 11, 2015, 12:31:48 PM
wizard, no the car was parked up when I got there....I just dont understand how a new part can be worn!
Title: Re: Phils 4thirty build
Post by: Monster on April 11, 2015, 01:35:32 PM
Sorry to hear that Phill.
Mine is the same re emissions. It will fail every time unless I get the engine to running temp before they test, then there's no problem, which isn't unusual.
Shame you can't find a tame MOT station. I'm under the car with the tester when he does mine.
Hope to see you at Stoneleigh.
M
Title: Re: Phils 4thirty build
Post by: Phils99 on April 11, 2015, 05:13:48 PM
Cheers Monster....

Pic 1, Okay so this is the car dropped off at Kwikfit for the MOT...

Pic 2, 3 and 4 when I returned to my failed MOT, they had attempted to put the roof up totally incorrectly which resulted in this gouge out of the pod, I have also noticed a scratch in the similar place on the other pod.....

Pic 4 and 5, it failed due to emmisions, but a good run should sort that, and also excessive play in the wishbone, I have now removed the wishdone and this is why!
The other wishbone has a full solid rubber bush fitted whereas this side only has one like this fitted, this gives the play in the rear wishbone bush as it shouldnt have play backwards and forwards, I am also thinking that if I  rotate this bush 90 degrees, that would probably fix it, but its still the wrong bush.
I will need to talk to DNA on monday about this as, if I can get this fixed before next saturday, I will get it retested free as they havent "put it through the system" as yet....as Monster says above they will redo the emission test as soon as I get there as I drive 15 miles so it should pass then I hope!
Title: Re: Phils 4thirty build
Post by: Wizard on April 11, 2015, 06:06:55 PM
Ouch....what did they say about the pod, I feel some compensation is due....!

More importantly, why where the messing around with your roof (I dont recall this being part of the MOT).
Title: Re: Phils 4thirty build
Post by: tbag on April 11, 2015, 07:48:52 PM
Ill dig out a solid bush on monday phil... I dont know why they are different they should be the same, will send it with the mirrors..
Title: Re: Phils 4thirty build
Post by: Phils99 on April 11, 2015, 09:12:42 PM
cheers tony, ill ring brian on monday to confirm.....
Title: Re: Phils 4thirty build
Post by: Phils99 on April 11, 2015, 09:14:18 PM
wizard, they were gunna put the car outside after the MOT, but it was raining...

I think the lesson for ALL builders is STAY WITH THE CAR for the MOT!!

I wont leave it again!
Title: Re: Phils 4thirty build
Post by: Furrari on April 11, 2015, 09:22:54 PM
I find you are treated differently if you go to a garage with a kit car (certainly a Furrari) rather than just a mundane car.  I can't do a lot of the jobs myself because of my back and hip so I have to have the work done for me but I often end up in the workshop telling them how to do the job
Title: Re: Phils 4thirty build
Post by: Lee22 on April 11, 2015, 09:56:17 PM
 Whilst you've got the lower arm off phil,
Get them sand blasted and powder coated mate..... Make them look a million dollars..!
Title: Re: Phils 4thirty build
Post by: Phils99 on April 12, 2015, 11:54:13 AM
Cheers Lee, as these are relatively new, they still look good, thats mainly muck on them!
Title: Re: Phils 4thirty build
Post by: Lee22 on April 12, 2015, 12:51:43 PM
Well gets hem cleaned then....!!

Lol
Lol
 ;D
Title: Re: Phils 4thirty build
Post by: tbag on April 13, 2015, 10:36:58 AM
Its in the post phil, and the mirrors... it will be with you by 1pm tomorrow
Title: Re: Phils 4thirty build
Post by: Phils99 on April 13, 2015, 12:18:17 PM
cheers DNA!

Ill keep an eye out for them....
Title: Re: Phils 4thirty build
Post by: Phils99 on April 15, 2015, 11:47:24 AM
yep, as good to their word the new parts were delivered yesterday! unfortunately I was busy last night, but I will fit the parts tonight..

Also, had Kwikfit on, and they are waiting for me to let them know how much they owe me.....Im thinking of asking for free laser tracking from them as that I know costs £65 plus extra if they have to adjust anything.
Title: Re: Phils 4thirty build
Post by: Wizard on April 15, 2015, 12:10:33 PM
To be honest I would be surprised if you asked for anything less than £300. It's a lot of work/inconvenience for you to be the work repaired. 

Or better still, let them come up with a figure as it may be a lot higher and you can go from there.
Title: Re: Phils 4thirty build
Post by: Phils99 on April 15, 2015, 12:35:27 PM
well, done the deal now, Kwikfit will do the front wheel balancing and full 4 wheel laser alignment for me for free, thats gunna be close to £150 worth of work.......

Talking of laser wheel alignment, have any of you guys had it done? what settings did you get the garage to use as obviously its not n MR2 anymore.

Kwikfit are a little dubious about if they can do it. we kind of agreed last week that if we pump in the MR2 figures and set it up like that...anybody got any experirence of having this done on their 4Thirty?
Title: Re: Phils 4thirty build
Post by: Furrari on April 15, 2015, 06:21:11 PM
I just used the MR2 settings.  As the settings are checked on the hub centrelines you are only checking toe in/out not caster or camber angle.  Not many places have caster/camber gauges as it's a bit specialised, more competion than road as they are not usually adjustable on a road car.

My Moskvich had adjustable front suspension.  1.5° negative on the front transformed the handling so it is worth checking if you can get it done.
Title: Re: Phils 4thirty build
Post by: rudycob1 on April 15, 2015, 08:25:26 PM
Phil,
When I did my suspension and fitted the adjustable shocks, I did a lot of research into this and this is what I came up with.

Year   Model   Caster   Camber       Toe-in (in.).    Steering Inclination(Deg.)
04 MR2    F       0.75 3.08   0.75   -0.47   0.06+/-0.08   14.52+/-0.75
           R.              0.75   -1.05   0.12+/-0.08   

These can be used as a starting point and it's what I used:
Front Camber.   Negative 1.25 degrees
Front Toe.           0.00mm
Rear Camber.    Negative 1.25 degrees +/- 0.75 L to R
Rear Toe.           1 to 3mm toe in total.

With the standard DNA suspension I do not think you will be able to adjust everything but see were you get to the above numbers.

I must admit, it transformed the way the car drove and felt.

See you soon.
Title: Re: Phils 4thirty build
Post by: Phils99 on April 15, 2015, 09:34:52 PM
great info Rudy, Ill take this with me on Saturday...

So I set about fitting the replacement bush sent from DNA.....

Pic 1, here is the new bush (left) and the one that was fitted (right), but as you can see, same problem as Lee had, the hole is too big for the bolt so I need to extract the sleeve from the old bush, unfortunately, I dont have  a 2.5 ton press....

Pic 2, I firstly cut the rubber of and then using a grinder I removed a part of the outer sleeve to reveal the inner sleeve

Pic 3, When I had removed a segment of the outer sleeve, I then used a puller to push the inner sleeve out..and yes, she is moving!

Pic 4, ...halfway there!...

Pic 5, shes out!!, phew, this took me over 1 hour to get this out!

I then hammered it into the new bush (which took some work as well!) and refitted the wishbone, all good now, no movement!

I fitted the replacement mirrors as well, so she is now all ready for the re test on Saturday...fingers crossed and hopefully it will be dry weather!
Title: Re: Phils 4thirty build
Post by: Spacecowboy on April 17, 2015, 06:25:49 PM
Nice work. Best of luck
Title: Re: Phils 4thirty build
Post by: Furrari on April 17, 2015, 08:46:14 PM
Played this game on a Maxi.  Great fun isn't it.  Just like a poke in the eye with a sharp stick.
Title: Re: Phils 4thirty build
Post by: Phils99 on April 17, 2015, 10:09:27 PM
well, what can you say, I sent my pods to DNA on Tuesday, they got them on Wednesday, resprayed and posted back to me so that I got them today! hows that for service!!

So tonight I refitted the pods and had to spend an hour lining them up again, as Kwikfit must have pushed them out of position by forcing the roof up with the pods unfolded!

So she is ready for MOT retest tomorrow....fingers crossed....
Title: Re: Phils 4thirty build
Post by: Paul79 on April 17, 2015, 11:16:31 PM
Good luck mate. Don't let her out of your sight. 😄
Title: Re: Phils 4thirty build
Post by: Phils99 on April 18, 2015, 10:07:57 AM
Update...emmisions passed! But only just! They were messing about for 20 mins revving it up and down to get the machine to pass it!

Also, he said the wishbone are FRONT bush still has too much movement on the passenger side?????
But, as I have had the issues with them, they will pass it anyway....so WE HAVE MOT!!

just getting the wheels balanced and laser tracking for free now as compensation for damaging my pods!! £150 worth of work.
Title: Re: Phils 4thirty build
Post by: Wizard on April 18, 2015, 10:39:54 AM
Fantastic result with MOT.
Title: Re: Phils 4thirty build
Post by: cheets on April 18, 2015, 01:18:11 PM
Nice one Bud  can what for that day :) 
Title: Re: Phils 4thirty build
Post by: ferrari feb 14 on April 18, 2015, 07:15:10 PM
That's great news on the mot phill , looking forward to seeing her in a couple of weeks,jd
Title: Re: Phils 4thirty build
Post by: Furrari on April 18, 2015, 07:25:06 PM
Immisions on a kit car?  I know of some kit cars that just happen to have the same immisions as the car in the next MOT bay, isn't that strange.  Fortunately mine is OK.
Title: Re: Phils 4thirty build
Post by: Paul79 on April 18, 2015, 09:25:56 PM
Well done Phil. The end is in sight. 😄😄😄
Title: Re: Phils 4thirty build
Post by: Phils99 on April 20, 2015, 09:16:28 PM
So.....time for some more interior work. I decided to have a go at fitting the dashboard and the air vents.

Some of you may remember that I have bonded the HVAC front into the centre airvent moulding you get with the dash kit, so now I needed someway of mounting the HVAC controls to enable the front panel, now bonded to the air vents, to screw back into it without any force.

I pondered on this for a while and started with a couple of metal brackets to extend the hvac control mountings forward enough, this became hard to do, as its hard to fix the bracket to the original hvac control mounting points and then to secure the hvac controls to the bracket...hmmm...then I had an idea! I just need to put a spacer behind a longer screw and I should be able to use the existing hvac control mounting screw holes....I just need some small tubes to use as spacers...I know...rivnuts!, I used a medium one plus a washer behind the top holes in the hvac control and a smaller one behind the bottom holes..perfect! it tightened up nicely and was held solidly in place at the correct position and angle, I then placed the centre airvent over it and made sure the top edge of the air vent sat nicely inside the cut out in the dashboard, it did and it worked perfectly!

Now, its only held in place by the 2 screws that secure the hvac front panel to the hvac controls, so, when I come to fit it properly, I think I will add a bit of velcro under the top edge of the centre air vent unit, this way it will be held solid and is still removable.

Pic 1, The centre air vent held in place and also I have added the new graphics for the controls and a set of "madmans" replica knobs!

Pic 2, this is the gap at the side I will need to fill, but I will just shape a piece of plastic to fill this nicely

Pic 3 and 4, I then just taped on the outer air vents to stand back and see what it would look like with all the dash in place, well pleased!...just need to sort the stereo surround out as I dont think I can cut out my existing PFL one as no way will it fit over the screen, I still need to find a facelift one, so Im still looking....

...and yes, I still havent done anymore with my centre console as this is going to need a lot of work and I wont have time to get it all done before Stoneleigh....
Title: Re: Phils 4thirty build
Post by: MADMAN on April 20, 2015, 10:17:11 PM
Hey Phil I love the HVAC unit blended in, it looks 100% better, another job for me when I get round to it
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: beemaman on April 20, 2015, 10:30:03 PM
Hi phil are you after a stereo surround ? If so I'm sure ive still got my stereo at work it came out a late 03 ) speed facelift model

Interior looks great buddy :)
Title: Re: Phils 4thirty build
Post by: Phils99 on April 21, 2015, 08:07:57 AM
cheers guys, its getting there!
Title: Re: Phils 4thirty build
Post by: Phils99 on April 21, 2015, 08:56:44 PM
bit more interior work, I removed all I trial fitted yesterday to fit it in for real....

Pic 1, I removed all of the MR2 vents so that they wont close up on me!  then removed the hazard warning switch, which was a pain to get out so I cut it out as all this will be covered by the centre vents...

Pic 2, I also removed the surround that actually holds the switch in place, as I will be able to bond this to the back of a plate in my centre console and clip the hazard switch into it to hold it

Pic 3, I then extended the wiring long enough to fit the switch into the centre console later on, I tucked the switch and wiring under the ashtray for now....

Pic 4, I then bonded the dashboard onto the MR2 dashboard and added some weight.

Tomorrow, I will bond on the "airbag" and the outside centre vents....its getting there now!
Title: Re: Phils 4thirty build
Post by: cheets on April 21, 2015, 11:35:43 PM
Nice work Phil :)
Title: Re: Phils 4thirty build
Post by: Phils99 on April 22, 2015, 08:28:15 PM
bit more interior work done...

Pic 1, Bonded on the outer air vents and the "airbag" to the dash

Pic 2 and 3, I wanted to make the instrument cowel removeable, so I used some dum-dum tape to fix this on, that way I just can pull it off when I need to get to my clocks as I plan to remove the 3 "tunnels" after the shows and have a nice flat open clock face like Madmans

Pic 3, I riveted the F430 piece you get with the interior kit to the centre vents and then I used the metal laser cut F430 sign that Rudy gave me...all those months ago...and glued each part over the F430 piece giving a 3D effect in metal!
Title: Re: Phils 4thirty build
Post by: beemaman on April 22, 2015, 11:17:42 PM
Brilliant work buddy nearly there :) txt me tomorrow about stereo I forgot today buddy sorry
Title: Re: Phils 4thirty build
Post by: cheets on April 23, 2015, 12:12:42 AM
Liking your work Phil :)
Title: Re: Phils 4thirty build
Post by: Wizard on April 23, 2015, 06:36:40 AM
Can't wait to see this at Stoneleigh. Looks great.
Title: Re: Phils 4thirty build
Post by: kalifornia on April 23, 2015, 07:20:25 AM
Not. Long to go for Stonleigh, just under two weeks. Looking forward to seeing the car
Title: Re: Phils 4thirty build
Post by: Phils99 on April 23, 2015, 08:12:33 AM
cheers guys!

During the MOT, I was watching whilst they tested the brakes etc, I noticed that my brakes lights are lighting up on the inside edge instead of the outside edge...looks like I have the lights in the wrong side...I then checked the fog lights, and yes, you guessed it, I have them in the wrong side as well! whats the chances of that!

Aw, well, looks like tonights job it to remove the diffuser reach up and change the lights over :-( ...removing the diffuser will be easier than removing both rear wheel liners!
Title: Re: Phils 4thirty build
Post by: beemaman on April 23, 2015, 10:29:02 AM
lol phil typical that isnt it.but then again theres nothing on the lighjts telling you which is which :(

you could remove wheels and cut out a square acess hole in mudcover to get to lights then make a slightly larger piece to go back on and scew over the top.saves all the removing of things in future,just the wheels
Title: Re: Phils 4thirty build
Post by: Phils99 on April 26, 2015, 07:21:13 PM
cheers guys! its been a long old build!

Today I was just pottering around with the car, I drilled holes under the doors to let out any water that gets in, I also took the seats out and hoovered the carpet ready for my replica seats coming hopefully Monday night.....

I then removed the rear diffuser, as, if you remember, I had actually fitted ALL the rear lights in the wrong sides!
The correct way is brake lights should light the outside half of the light unit and the fog lights should light the inside half of the light unit.

So I removed all my lights and swapped them over, now, one thing I have always wanted to do was have my break lights light up the full circle of the light unit, so I decided to investigate if this is possible, and guess what? its absolutely VERY easy to do, as the light unit is already fitted with 2 dual filament bulbs, so, unscrewing the bulb holder from the light unit and looking inside, you can see in Pic 1 circled that the metal part that lights up the brake light has a gap in it, I stuck a screwdriver in to bridge the gap and both bulbs lit! sorted!

Pic 2, I then took a pop rivet and chopped off the bottom and most of the "pin" part...

Pic 3, ...and then forced it into the gap to bridge it!

Job done! I reassembled and it now works a treat lighting up thew full circle.

Simple mod if you want the full circle of brake light.

Also, I was looking at the ashtray part and I think I am going to cut this out to make a surround for my stereo using my spare one from the green machine (which I will replace later), I started it, but my dremel cutter adapter broke, so I will have to get another one to finish this job.....
Title: Re: Phils 4thirty build
Post by: cheets on April 26, 2015, 07:38:09 PM
Liking the mod on the light Phil think i will be doing that one :)
Title: Re: Phils 4thirty build
Post by: beemaman on April 26, 2015, 07:43:03 PM
Hi phil

Was my stereo bezel no good for you buddy ?? Did you get to measure it ?
Title: Re: Phils 4thirty build
Post by: Phils99 on April 26, 2015, 11:03:19 PM
sorry wayne, yea I did measure and I think its slightly taller than the bezel thats you have so I think mine is actually a big unit!

Thanks for the measurements mate, I am gunna try cutting up the ashtray part and see how it works....
Title: Re: Phils 4thirty build
Post by: Phils99 on April 27, 2015, 08:24:36 PM
Look what I picked up tonight!!
Title: Re: Phils 4thirty build
Post by: Wizard on April 27, 2015, 08:42:30 PM
Wow. I love those seats. Looks brilliant.  Will they be in for the show??
Title: Re: Phils 4thirty build
Post by: Paul79 on April 27, 2015, 08:51:33 PM
Wow. I love those seats. Looks brilliant.  Will they be in for the show??
Before the show? They'll be in before Emmerdale finishes tonight! Lol
Title: Re: Phils 4thirty build
Post by: Furrari on April 27, 2015, 08:56:29 PM
Just like mine are, the horses are too big.  Like me you probably don't care.
Title: Re: Phils 4thirty build
Post by: Wizard on April 27, 2015, 09:06:32 PM
Horses looks brilliant to me.
Title: Re: Phils 4thirty build
Post by: MADMAN on April 27, 2015, 10:57:05 PM
and me,
 they must be fitted by now ;) ;)
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on April 28, 2015, 08:18:25 AM
cheers guys...sorry, not fitted yet as I needed to bond on the headrests with dum dum as he left that for me to do.

I also, if you remember, have to swap over the seat belt clips as they are different to the green machine seats I have in at the moment...and I would also like to temp wire up my heated seat as it may be cold on Sunday morning!

I will hopefully do all the above tonight and get them in place, then the only big thing left for the show is a good clean on Saturday!
Title: Re: Phils 4thirty build
Post by: Phils99 on April 28, 2015, 08:02:18 PM
They are in!!
Title: Re: Phils 4thirty build
Post by: Wizard on April 28, 2015, 08:05:52 PM
Phil. They look excellent. Really changes the whole look of the car.
Title: Re: Phils 4thirty build
Post by: Paul79 on April 28, 2015, 09:01:49 PM
Well done matey. It's been along road. So glad ur now at the end. Looking forward to seeing the car (and you) at weekend.  ;D
Title: Re: Phils 4thirty build
Post by: Monster on April 28, 2015, 10:16:19 PM
Looking great Phil and just in time the start of the show season. It won't be the same at Stoneleigh without the Green Machine demonstrating the before and after build!
M
Title: Re: Phils 4thirty build
Post by: Furrari on April 28, 2015, 11:11:16 PM
Forget the red one, just bring the green machine.   :-)
Title: Re: Phils 4thirty build
Post by: Lee22 on April 29, 2015, 12:10:32 AM
Very nice Phil...

Really loving the look now..
Lee
Title: Re: Phils 4thirty build
Post by: MADMAN on April 29, 2015, 08:50:43 AM
Looking Great Phil, I bet you cant wait for this weekend, but I will miss the green machine.
Someone please buy it and contine bringing it to shows or it will defo be Missed :'(
MADMAN 8)
Title: Re: Phils 4thirty build
Post by: Phils99 on April 29, 2015, 10:56:19 AM
yea...someone please buy it!....just need to fix the engine at the moment...oh and replace a couple of bits I have "borrowed" for my 4thirty!
Title: Re: Phils 4thirty build
Post by: Phils99 on April 29, 2015, 09:04:04 PM
Pic 1, tonight I managed ti fix the supplied rubber into the slots on the rear deck where the T pieces for the roof are.

Pic 2, I then made templates for the wing mirror cover plates...

Pic 3, and then shaped a pices of plastic I had to fit into the opening. I think fixed it with dum-dum so these can easily be removed if needed.
Title: Re: Phils 4thirty build
Post by: OXO on February 13, 2017, 10:31:52 AM
I have to say how thoroughly enjoyable it has been watching your build........ Thanks for posting it !
Mick
Title: Re: Phils 4thirty build
Post by: Phils99 on February 18, 2017, 12:46:21 PM
it was my pleasure!
Title: Re: Phils 4thirty build
Post by: Phils99 on March 15, 2019, 03:57:29 PM
Hey! Hi all you DNA owners/ members, yes, I am still alive and still visit this forum now and again.

I have an app on my phone which lets me know the status of my cars MOT's and it just recently let me know that my MR2/DNA 430 has passed!

This got me nostalgic about it and lead me to re-read my whole build thread!

It was an amazing experience backed by incredible members of this forum. I enjoyed every minute of it.

I started the build on Oct 1st 2012, and finished it for the Stoneleigh show 2015 so 2.5 years in total, but this included 1 divorce, 2 house moves and 3 job changes!

I still attend Stonleigh every year just to meet up with the great car friends I made on here and met over the past 6 years. I will defo be at Stoneleigh again this year (hotel booked) and look forward to having a great time with you all again as always.

Sure wish DNA would create a kit that can be bought and fitted by just about everyone as they used to as these build threads were very interesting to watch and admire.

Anyway, just wanted to say Hi and many many thanks to all of the guys on here who helped me in one way or another (just about everyone!!)

Best wishes and see you all at the show!
Title: Re: Phils 4thirty build
Post by: MADMAN on March 16, 2019, 09:32:24 AM
A up Phil, you joining us in convoy again? This time we wont follow you ;D
Title: Re: Phils 4thirty build
Post by: Phils99 on March 18, 2019, 10:33:27 AM
hahahahahaha yea defo join the convoy.....at the back!!

it was due to my legs not working properly after jump starting that monster car in the services car park!!