Exhaust Hanger Mark 2

Mark 2 exhaust hangers, these use the rubber mounts from a BMW 840Ci Sport. There is 3mm steel plate than connects the exhaust boxes to the hangers.

A new bolt is welded in on the right side of the hanger, the other is the one form the fuel tank strap.

Driver side bracket, this one has some stress on it but the rubber mount is off a 12 year old car so the rubber has gone soft. A new pair will need to be ordered to finalise this.

The plates need a coat of paint and this can be marked as done.

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Clutch Mark 2 Complete

The new clutch system is now installed. The master cylinder has more than enough capacity to dis-engage the clutch without pushing it all the way down. The pedal position can be adjusted with the thread on the master cylinder so we’ve moved the clutch inline with the brake pedal. Due to the different leverage on the clutch it is now very easy to use. Only time will tell if all the problems are solve once we can go further than the end of the drive!

Constructing the scuttle panel re-enforcement plate

Heating along the cut to bend the 3mm steel.

Re-enforcing the pedal box

The metal is welded on in various places to strengthen the pedal box.

Welding complete on the pedal box

Scuttle re-enforcement plate painted and bolted in place, it bolts on to the bar than runs from one side of the car to the other. There is no flex at all when the clutch is operated now.

Pedal box and new clutch assembly reinstalled in the car.

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Clutch Mark 2

Connected up the clutch this evening, the bite point is right at the bottom of the pedal travel, but is really controllable. It means the clutch will sit higher up that the brake at the moment so we’ll have to see how it goes. The whole scuttle bends all over the place so reinforcement is required now.

And finally warm weather – well not freezing anyway :o)

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Clutch Mark 2

Done some work on the new clutch setup:


Bolts through the top of the scuttle to hold the clutch master


Wilwood clutch master mounted to wilwood clutch pedal frame and then bolted to the scuttle.


The scuttle will need some re-enforcement as does the pedal box.

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Body panels

All the body panels are off and ready for paint!

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Loured Up

After not having much success with the bead roller I went to go see http://www.coollouvres.com/ today, here are the results, I’m really happy with these:

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Bodywork final stages of prep for paint

Rough fill in of the holes in the tub with 8 layers of glass to give it plenty of strength.

Rough fill in of the holes in the tub with 8 layers of glass to give it plenty of strength.

Tub hole cover from the back

Tub hole cover from the back

New side repeaters fitted - these need the hole enlarging a bit.

New side repeaters fitted – these need the hole enlarging a bit.

New scuttle side panels sitting snugly with the new repeater above.

New scuttle side panels sitting snugly with the new repeater above.

Vent hole cut and cover fitted

Vent hole cut and cover fitted

Mirror holes filled in (the ones nearer the front they were in the wrong place!) and vent holes.

Mirror holes filled in (the ones nearer the front they were in the wrong place!) and vent holes.

Back of tub sprayed black - hides all the modifications.

Back of tub sprayed black – hides all the modifications.

Bonnet cleaned up ready for louvres and the hinge holes sunk slightly further to allow the screws to sit more flush.

Bonnet cleaned up ready for louvres and the hinge holes sunk slightly further to allow the screws to sit more flush.

Fibreglassing experiment - this will form an attachment for any future rear diffuser.

Fibreglassing experiment – this will form an attachment for any future rear diffuser.

Fibreglassing experiment - this will form an attachment for any future rear diffuser.

Fibreglassing experiment – this will form an attachment for any future rear diffuser.

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Wiper video

I took some video with my phone so its pretty cruddy quality but shows the wiper motion:

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Bodywork update

A few more things checked off the list:

  • Finished the scuttle side panels
  • Opened up the indicator holes on the scuttle to fit the new ones
  • Rear end break down
  • Step one of filling the seat belt holes in the tub

I recommend everyone take their tub off after a year and check for rust issues, we’ve got a few area’s that need to be cleaned up and protected.

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Scuttle side panels

New scuttle side panel without louvres compared to the original with louvres. The new one also now has folded back edges which gives a much better edge.

New scuttle side panel on the passenger side with folded back edges.

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