Bodywork

Centre console, and rear end

The centre console coming together, this will also act as a duct for heater down to your feet. There’s also a 12V supply in the side of it for the all important sat nav (or I’d get very lost all the time):

Here is is from a higher vantage point:

The 77MP’s styling fits the car quite well:

All the wiring needs a final tidy up after settings are finalised.

Door hinge bracket, one of four. The metal the door is bolted to is far to thin, it flexes all over the place. Hopefully these will add enough structure to fix this.

Exhausts bolted up, bumpers fixed in place, rear lights in place and working. Just needs the other wing and a number plate.

Interior

Fuse box & speakers

Mk 2 fuse holder bracket<br />

Mk 2 fuse holder bracket

This bracket also holds the wiper motor. The clamp has been moved up a bit to reduce flexing.<br />

This bracket also holds the wiper motor. The clamp has been moved up a bit to reduce flexing.

The centre console is taking shape with a small recess to keep your glasses.<br />

The centre console is taking shape with a small recess to keep your glasses.

Managed to find some room to fit a speaker above the steering column.<br />

Managed to find some room to fit a speaker above the steering column.

There's some sides and top to try and keep the front and back separated as much as possible.<br />

There’s some sides and top to try and keep the front and back separated as much as possible.

Once the dash is in you can't see it any more.<br />

Once the dash is in you can’t see it any more.

Interior

Speakers, hazards and other stuff

Nose cone and centre console

Nose cone fitted.

hmm pretty colours

Starting to piece together the centre console

Two supports cut and shaped to get the angle of the radio correct with enoughclearance for the rear of the radio.

Radio supports glued.

Just need to make up some sides to hold the midbass speakers under the dash.

Bodywork

Interior and rear lights

Dash board re-trim without glove box (wiper motor in the way)<br />

Dash board re-trim without glove box (wiper motor in the way)

Rear of re-trimmed  dash showing pod for speaker<br />

Rear of re-trimmed  dash showing pod for speaker

Divers side behind the dash<br />

Divers side behind the dash

Test fit on car, the mount holes needed drilling out as the paint had filled them a bit.<br />

Test fit on car, the mount holes needed drilling out as the paint had filled them a bit.

The speakers could do with a grille mesh to finish them off but other than that it is coming together.<br />

The speakers could do with a grille mesh to finish them off but other than that it is coming together.

Rear lights installed with new waterproof plugs - a bigger job than you might expect!<br />

Rear lights installed with new waterproof plugs – a bigger job than you might expect!

Chassis

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.

Chassis

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.

Chassis

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)

Chassis

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.