Radiator Return Pipe
Since the car was built the return radiator hose as been a long flexi pipe, this was never a good solution. At some points the pipe rubs which eventually would...
Varex Exhaust Video
Had a chance to record some new footage of the exhaust. XForce Varex VMK51-250 variable volume exhaust - it's pretty much straight through when it is open. Here's a few...
Boot interior rear
The final trim piece is for the rear of the boot interior. Here's the initial planning using foam board. Transferring the foam board to aluminium. Test fit before bending. Bends...
Boot side panels
Next boot related project are the side panels. These I'm making out of aluminium, line with carpet and some rubber trim to seal them against the tub. Passenger side panel...
Harness Holes Be Gone
I made some blanking plates to cover holes no longer needed in the tub. These are aluminium, painted black then lined with rubber and held on with rivnuts, cup washers...
All the Brackets
Bracket Number 1: The return pipe from the radiator to the header tank has always been attached with a zip tie holder, but only double sided taped on. Every time...
Boot lid
This is a project that's been been waiting for me to get to it for a very long time. The boot area has always been open with just two smaller...
New front wing stays
The front wing stays rusted and broke again, did a temporary fix a few months ago, but finally it's time to make some new ones which will hopefully be more...
Carpet
Woolies sell rot free carpet, I thought it would be worth a try see how well it will last in a car without any interior weather proofing. Here's the before...
2019 MOT – handbrake failure and fix
So the MOT tester is a beast of a man and ripped both handbrake cables clean off the mounts! Better it failed here than in an emergancy though. The orginal...
Water leek, from back of the head
Another week, another new fluid all over the floor! Coolant this time from the rear port on the cylinder head. That's the pipe that goes to the interior heater core:...
Fuel pipe refresh, car pee’d all over the floor!
Car pee'd on the floor... It's a bit drippy here at the back, but also at the front on to the start motor - not overly safe and smelled pretty...
Coolant flush and refresh
This drain plug has been leaking forever, the drain part is reverse thread and normal thread into the radiator. The thread into the radiator needed more PTFE. Due to topping...
Front indicator stalks refresh
The front indicators were starting to rot pretty badly, replacements are not very expensive so I decided to change them for new. The new ones are little bit shorter than...
Seat Repair
The Cobra Roadster 7 look nice, but the construction quality is questionable at best. After 6500 miles the driver seat broke in two. I'm very happy the nice SVA man...
Upper wishbone refresh and wishbone mounting rod
I changed the upper bushes today. They were rally design ones, which I've now replaced with Powerflex. I thought the bushes had worn as things didn't look straight anymore. Turns...
Reassembly, paint, lighting, electrics
The rear wings, tub and spare cover are back from http://www.specialisedpaintwork.com/ for some touch up work and removal of all the stone chips on the wings! The wings were starting...
3 point reel seat belt conversion
ziptie test, safety 3rd! Hole cut for threaded belt insert Test fit of new piece Use the lathe to clean up these spacers Reel mount Reel mout welded in Upper...
Rear rust clear up
Doing some clean up work, the Sportster has been on the road for a while now so it was time to check for rust and clear anything up Little bit...
3D Printed light bracket finalised and dust cover for LED centre lights
Part evolution from initial concept to final co-polyester print, shown at the front the traditional bulb clear lens, LED amber indicator and LED ring light. The final part: Test fit...
3D Printed light brackets Version 2 test
Version 2 on the left, much smaller than the inital version: Some clearance to fit two next to each other on the Sporster The part is still more than strong...