GTS Panther kitcar

PaulYDP

RMS Regular
Messages
3,894
Location
tbc
Drives
R1 Turbo
You might want to grab a cup of tea before reading this. I've a bit to cover before getting caught up to date as I've been working on this project since last August (albeit not at a great pace!)

First off a bit of background. Those of you that know me while know I've previously built a Tiger kitcar which I built and put through the SVA, then modified and raced for a season. There should be a thread around here somewhere...
I sold that one back in January or February 2015 as I had no garage at my new house and so made no sense having it. Instead I used the funds from the sale to build a garage with the view of getting another kitcar at some stage in the future.

Roll forward to June 2017 and a spotted a track only car for sale with a ZX9R fitted, same as was in my Tiger. It came with a trailer and all and was at such a good price I just couldn't go past it. So one Friday morning my dad and I set off to drive to Sheffield to pick it up. It really was an extremely clean well built car with a number of trick bits fitted but to cut a long story short, I used it for one sprint at Kirkistown then decided to strip and rebuild it which took a lot longer than planned and escalated a bit.

As I approached the end of the rebuild I had a real itch for a road-legal car again as I wasn't sure how much I'd realistically use the track car... so I started looking around and just kept the feelers out to see if there was anything suitable. I missed out on a car not long after starting to look but after another few weeks a car popped up in Liverpool that seemed like it might fit the bill of what I was looking. A road legal car, in budget and with a bike engine. Getting all three of those was going to come at a compromise though of course, specifically the in budget requirement as I still had the other car. That compromise in this case was that it didn't run! Even so, due to the price there was a lot of interest in the car but I got talking to the owner and struck a deal - I wasn't missing out on this one! I bought it blind and just arranged for Bartlett Transport to lift it which all went well. There is always a risk buying blind of course but I was confident it would have to be pretty bad to not work out worthwhile!

The day it arrived....
3m10jz


mn10jz



So a little bit about the car - it was first registered back in 2004 so it's been on the go for quite a while. It's most recent MOT expired in 2017 and it had been laid up since (or even before that!). That was pretty evident when I got it home as it was filthy and a bit tired looking! Somewhere along the line (2016/17) the engine blew up on a track day... From doing some research the engine had been in it since at least 2010 in it's current format so it had lasted pretty well given it was a Yamaha R1 engine with a turbo strapped on! The owner sourced a new engine (with 16k miles on) and had started the engine swap, however due to one thing or another the swap was never completed, the car was pushed into a corner and left there! So when it arrived to me the new engine was mounted in the engine bay but with a lot of things not connected up or still to be swapped over from the original engine - the orginal engine was sitting in the passenger seat!

I rolled the car into the garage after it was delivered and that's were it would sit until I had the track car finished and sold as I couldn't keep two of them!

go10jz


Thankfully the track car sold pretty quickly and the focus turned to the GTS. As with many projects though I had a decision to make - just get it up and running and use it as is for a while, or strip it down and replace/redo anything that needed it and leave it the way I wanted it from the start. I decided I would do a little bit of stripping initially to see what I found and then go from there, I hadn't stripped it back very far until I decided to go the whole hog. The eagle eyed among you might have already picked up on a few things that influenced this decision.

One thing with buying a kit car of this age is that it's been through a few owners all with different ideas and with some odd decisions made along the way!

So things I wasn't happy with... Firstly the bodywork - when the car arrived the nose cone was only sitting on and had been through the wars some what with paint chipped off in various places, then the side panels had been cut at some stage and to hide the join a piece of black aluminium had been tiger sealed on. With the black section removed it revealed that not only was the join in an odd position exposing the footwell on both sides but the two sections were also different shades of orange - that just wasn't going to work. Nothing else for it but make new side panels myself. I feel like I should call out at this point that I'm not a mechanic/engineer/bodywork specialist so things are far from perfect but I enjoy the learning experience!

gs10jz


The other thing that I just couldn't have was the roll cage, more specifically the front hoop and the centre roof bar! Not only did I not like the shape of the front hoop but someone in their wisdom had drilled holes in it and fitted rivnuts so they could attach a perspex screen!

pt10jz


Again, nothing else for it but chop it out!

zv10jz


Once I'd that chopped out I set about making the new aluminum side panels and flared panels. To fold these I decided to also make my own sheet folder which worked out pretty well considering...

nw10jz


1w10jz


ux10jz


At this stage it was late August and I decided that my focus would be on completing the bodywork - I would be spraying in my garage and so I needed the outside temperature to be decent so that I could get the best results in such an environment. I started the ardious task of repairing panels where necessary, sanding and preping everything. This is by far my least favourite thing to do! Unfortunately as I reached the end of this task (early September) I injured my right wrist quite badly which has really hindered progress from this point forward. That resulted in me having surgery on it at the start of January this year and so I'm only now getting back on my feet. Anyhow, I pushed on as I wanted the painting completed while the weather was still good, it hindered me but the results were just about acceptable.

Temporary spray both...

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Some paint laid down!

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You may recognise it as the same colour as the track car and you'd be right! I'd enough paint left over from that one to do this one, so it's going to be another Porsche Voodoo Blue car! It's far from perfect but still an improvement from what it was before I think.

From here on in progress was extremely slow, my right arm was out of action for large periods and there is only so much you can do with one working arm! My dad did however come up on a number of occasions to lend me a hand and so I was able to make some progress on the roll cage. As the remaining part of the cage was in 38mm CDS I wanted to stick with that for the rest of the cage - unfortunately getting someone that could bend it locally proved difficult and so I ordered it in pre-bent from a company in England. This wasn't entirely successful though as will be seen in a photo shortly... I set about working out how to tie the existing side bar into the new front and also how I'd attached the front hoop to the car! I opted for running a 42mm CDS tube across the car and making two mounting plates out of 5mm steel. The plates had a 42mm hole cut in them and they were welded to the chassis, the tube was then welded to the steel plate. This was then the pickup point for the front hoop and side bars. A lot of measuring and working out was required to make all this work. It was my first time undertaking something like this but I took my time and got there in the end. It was only at the stage of tacking the front hoop on that I realised it wasn't made exactly as per the diagram I had provided and I just couldn't stand the look of it! (Looking back photos are limited from this time)

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In the interm period I had found a guy outside Ballymena that could bend 38mm CDS having bought all the equipement for another project (Muppet Motorsport) and so I got in touch with David to see if he could make me a new hoop. I gave him the dimensions and also left the one I had up to him so he could get the feet width perfect as that was crucial to working with the bar already welded in place. He turned it around really quickly and it was perfect! I had to set about getting it cut to the exact height and then notching it etc again. I notched all the tubes myself with an angle grinder, not prefect but good enough to get a strong weld on them (I'm also not a welder but have done a good bit of practising!). I got it all welded up and a coat of paint on it over Christmas (I had some use of my arm back and wanted to get as much progressed over Christmas as possible with my surgery approaching in early January and not knowing how long I'd be out of action for).

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m010jz


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7010jz


t110jz


0210jz


That's all for now, I've more updates that'll come when I’ve time to put it altogether
 
Last edited:

Dave..

RMS Regular
Messages
10,037
You might want to grab a cup of tea before reading this. I've a bit to cover before getting caught up to date as I've been working on this project since last August (albeit not at a great pace!)

First off a bit of background. Those of you that know me while know I've previously built a Tiger kitcar which I built and put through the SVA, then modified and raced for a season. There should be a thread around here somewhere...
I sold that one back in January or February 2015 as I had no garage at my new house and so made no sense having it. Instead I used the funds from the sale to build a garage with the view of getting another kitcar at some stage in the future.

Roll forward to June 2017 and a spotted a track only car for sale with a ZX9R fitted, same as was in my Tiger. It came with a trailer and all and was at such a good price I just couldn't go past it. So one Friday morning my dad and I set off to drive to Sheffield to pick it up. It really was an extremely clean well built car with a number of trick bits fitted but to cut a long story short, I used it for one sprint at Kirkistown then decided to strip and rebuild it which took a lot longer than planned and escalated a bit.

As I approached the end of the rebuild I had a real itch for a road-legal car again as I wasn't sure how much I'd realistically use the track car... so I started looking around and just kept the feelers out to see if there was anything suitable. I missed out on a car not long after starting to look but after another few weeks a car popped up in Liverpool that seemed like it might fit the bill of what I was looking. A road legal car, in budget and with a bike engine. Getting all three of those was going to come at a compromise though of course, specifically the in budget requirement as I still had the other car. That compromise in this case was that it didn't run! Even so, due to the price there was a lot of interest in the car but I got talking to the owner and struck a deal - I wasn't missing out on this one! I bought it blind and just arranged for Bartlett Transport to lift it which all went well. There is always a risk buying blind of course but I was confident it would have to be pretty bad to not work out worthwhile!

The day it arrived....
3m10jz


mn10jz



So a little bit about the car - it was first registered back in 2004 so it's been on the go for quite a while. It's most recent MOT expired in 2017 and it had been laid up since (or even before that!). That was pretty evident when I got it home as it was filthy and a bit tired looking! Somewhere along the line (2016/17) the engine blew up on a track day... From doing some research the engine had been in it since at least 2010 in it's current format so it had lasted pretty well given it was a Yamaha R1 engine with a turbo strapped on! The owner sourced a new engine (with 16k miles on) and had started the engine swap, however due to one thing or another the swap was never completed, the car was pushed into a corner and left there! So when it arrived to me the new engine was mounted in the engine bay but with a lot of things not connected up or still to be swapped over from the original engine - the orginal engine was sitting in the passenger seat!

I rolled the car into the garage after it was delivered and that's were it would sit until I had the track car finished and sold as I couldn't keep two of them!

go10jz


Thankfully the track car sold pretty quickly and the focus turned to the GTS. As with many projects though I had a decision to make - just get it up and running and use it as is for a while, or strip it down and replace/redo anything that needed it and leave it the way I wanted it from the start. I decided I would do a little bit of stripping initially to see what I found and then go from there, I hadn't stripped it back very far until I decided to go the whole hog. The eagle eyed among you might have already picked up on a few things that influenced this decision.

One thing with buying a kit car of this age is that it's been through a few owners all with different ideas and with some odd decisions made along the way!

So things I wasn't happy with... Firstly the bodywork - when the car arrived the nose cone was only sitting on and had been through the wars some what with paint chipped off in various places, then the side panels had been cut at some stage and to hide the join a piece of black aluminium had been tiger sealed on. With the black section removed it revealed that not only was the join in an odd position exposing the footwell on both sides but the two sections were also different shades of orange - that just wasn't going to work. Nothing else for it but make new side panels myself. I feel like I should call out at this point that I'm not a mechanic/engineer/bodywork specialist so things are far from perfect but I enjoy the learning experience!

gs10jz


The other thing that I just couldn't have was the roll cage, more specifically the front hoop and the centre roof bar! Not only did I not like the shape of the front hoop but someone in their wisdom had drilled holes in it and fitted rivnuts so they could attach a perspex screen!

pt10jz


Again, nothing else for it but chop it out!

zv10jz


Once I'd that chopped out I set about making the new aluminum side panels and flared panels. To fold these I decided to also make my own sheet folder which worked out pretty well considering...

nw10jz


1w10jz


ux10jz


At this stage it was late August and I decided that my focus would be on completing the bodywork - I would be spraying in my garage and so I needed the outside temperature to be decent so that I could get the best results in such an environment. I started the ardious task of repairing panels where necessary, sanding and preping everything. This is by far my least favourite thing to do! Unfortunately as I reached the end of this task (early September) I injured my right wrist quite badly which has really hindered progress from this point forward. That resulted in me having surgery on it at the start of January this year and so I'm only now getting back on my feet. Anyhow, I pushed on as I wanted the painting completed while the weather was still good, it hindered me but the results were just about acceptable.

Temporary spray both...

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Some paint laid down!

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You may recognise it as the same colour as the track car and you'd be right! I'd enough paint left over from that one to do this one, so it's going to be another Porsche Voodoo Blue car! It's far from perfect but still an improvement from what it was before I think.

From here on in progress was extremely slow, my right arm was out of action for large periods and there is only so much you can do with one working arm! My dad did however come up on a number of occasions to lend me a hand and so I was able to make some progress on the roll cage. As the remaining part of the cage was in 38mm CDS I wanted to stick with that for the rest of the cage - unfortunately getting someone that could bend it locally proved difficult and so I ordered it in pre-bent from a company in England. This wasn't entirely successful though as will be seen in a photo shortly... I set about working out how to tie the existing side bar into the new front and also how I'd attached the front hoop to the car! I opted for running a 42mm CDS tube across the car and making two mounting plates out of 5mm steel. The plates had a 42mm hole cut in them and they were welded to the chassis, the tube was then welded to the steel plate. This was then the pickup point for the front hoop and side bars. A lot of measuring and working out was required to make all this work. It was my first time undertaking something like this but I took my time and got there in the end. It was only at the stage of tacking the front hoop on that I realised it wasn't made exactly as per the diagram I had provided and I just couldn't stand the look of it! (Looking back photos are limited from this time)

IaGU_Dq9Nic43K17H4Q2D8ebFy2-6IhkVx3TeCj-Z0Zlv_uflMzNvvmojnU6XLZEtsUrUZK704Uf0J-upAIwe6XRSENWLXY1DlUMXJTXQSENApknS-ZxaHLpZRJnevKDd9EVk975O4eg7TW-8yTofDisthRYQkQujIcPqm_C7OxBaclbBhwF4pi18DqIxAe3AozKcjEiPv3SR9NpZDdNjmOszLJD3RKpCdE4nClSMEFlSkdQfvyZPKyUOhssf818SbYXMU6ehbr8XS7X-BtxcPslPyTXCU_SLMZ4mKTnw7hdsLIMdqFU-ijZGIkbOUOb1TfL-561zUmYbaGeGnFuAk6ML1PtwI1fDbwiQvOWVRNPx1OMqu38C8Wfg-mkWPmi7bSsKy6pD0rn2gWNHgNqJllUP9HTBChT-BVotpPR2aDrs5rozLyV-CQoM29mGeJ72dl6Cmu-cXz3N-qFI0vWHF0fd6XTECMPL4DmUR-4tAgIw5pEaJwnhkJEB1K-HoCeHxHwT7xhu5u-i15Ix_hS4ld5VugQc4pTc5Dx09MH2XhNsMbJxykHtcDd9E4Gm2opiMeSqTTVg0Fq8SzUEMTbtL3ADxlZMibiODOp8C-bYvDetYWnnjMGdUzfJ3NoCeYE0nAF-_5GtY2SgNM7pQoxC0jT3RkmBLpbm-fI8UmVHZShMRk7bnMvSqGv=w3360-h1890-no


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In the interm period I had found a guy outside Ballymena that could bend 38mm CDS having bought all the equipement for another project (Muppet Motorsport) and so I got in touch with David to see if he could make me a new hoop. I gave him the dimensions and also left the one I had up to him so he could get the feet width perfect as that was crucial to working with the bar already welded in place. He turned it around really quickly and it was perfect! I had to set about getting it cut to the exact height and then notching it etc again. I notched all the tubes myself with an angle grinder, not prefect but good enough to get a strong weld on them (I'm also not a welder but have done a good bit of practising!). I got it all welded up and a coat of paint on it over Christmas (I had some use of my arm back and wanted to get as much progressed over Christmas as possible with my surgery approaching in early January and not knowing how long I'd be out of action for).

_la40XOlPqRc_87wTTRMG2E5E8gP2cfJe9sv6s9Ctz_rK7bXwJEk2v93S50KZmU6RA-VKs3oWoYgnjrb35snEzSCjgHGhspH8gJVdCWvLQ7lj45v0gHPfOBQTBAUow06WlmH7KCl9zbEAaucy1qfXTyCd9O1RO5YH81MtguLiGDfXSdQmkw3pSVGhSdH4B07necxvX68f7vgTvAf856pwFug34d-lES2DtIcpx405Wr_1iWwwkfHUzAF-jasiprU_l3WGbVNgwU-5HPr53de4HxiOKeIlPYkyQrQ-8SrtFLRveP011ka15EVMCu573aj1MzRqLRPm-Q4QhuvxC94mKN5CervD_kN8Mb3ev70KKPTD-qPbNDLwPLU5zYh301nRAB9kdMHVkIk0o0RjX2k3FlKM9SE9YAh2zLdfTH39mP_vkUwKrsEea2wYXQIsu0xi4ZkPnDeOBwW67CxK3HgtWIK1oWMcndTmwy-hfOWPUAtoez3bj2YFf2zyhyWLLyU2EskYwA6tkP0odYFfNpDy07bmMZPTUIyqSe_COEtGh4EzPgK23Qt4RmyANRGuOW5lM4RfM3ASQ8EV233Bmc4ITePgxSl5lSYXwwV2hZ_NXiU-35OWAjlvHHOtXdidPMkG2n2_al9ihW1hg6FzkweXaiCGD5ke1tkOeGDJglD-tdaHvNM8cOMLpIO=w1432-h1908-no


LrP7DuT-UZW6i8X06AxHpBPkz0a3sH3uQ8DDaXQuTkviWcY1rpMDrxf7DbIiyFaUFazLxVd-BFOnhKfV-qrqF9F-xJswGQGEYQBRomdLTby76ZBhOzhgzfpw1xDxFoskqCDayN_gFO0FHIFifTCMhCDKcWU_6rVNr-6Bu78FXyDwqs6AYUGsKZj9drKFT7C8CoT7PpdQMMUCbfNtwXZHHcW9hbhwF0rOI536FgCGBwr2NlmXwf9qu8eeKqkNBcBM-Hs3YuAV2-7JQEy05ONVXK9YPLHpDJLh5ds6v5_7XUrHNCY6C0XkeHA8UuKxI-gK-9cROWQQA9YXZfTMBxRzHiWQtqXs97e83hrod34I2axvRxjuAhyaG0BoRjVAjKTYMDf45zYK8vmz0Oxi2dhd7FwVsQJ99nakgz0X-6kUccpNV8BTNTjNCLMpnE9GuTzOrLuLy_Kpf8Br_JBdHQzgVHUOPvSkuOiCKF6-BXYtFaM5O6m9SsGq2qUtoSymh1kS_1eT6v4yJRFOr2CqyoZXLJI_mqNC-UbPui1nvxeN9RYdS9j4jqZo6qmTs1z1uIkYHetCYHRibW2-bmCts-bkF0i7SO1Bu2cP0eVt8CrHeEu5puCFTmTIsMyAFnwsbTIkT3cx6_7GkQ875hlGkekBGYElWS1iNWaCezCHvfxIrEqLaddTRMB9vFwW=w2544-h1908-no


m010jz


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7010jz


t110jz


0210jz


That's all for now, I've more updates that'll come when I’ve time to put it altogether
Great write up.
Good luck with the work ahead, I think the blue really pops.
 

PaulYDP

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PaulYDP
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So once I had the cage finished it was on to the next thing that I wasn't keen on, that was the pedal arrangement and the fact the brakes were all off one master cylinder with no easy means of bias adjustment. The pedals themselves looked tired and basic so I treated myself to a Christmas present of a new CompBrake pedal box, it's a nice bit of kit. It took a heck of a lot of cutting to get the old pedals out with not much room for getting a grinder in but I got there and got the new pedal box in.

(I appear to have no photos of the originals but safe to say it was basic....)
iei1jz


vfi1jz



Next I rubbed down and painted the chassis. Paint was flaking off all over the place so I sanded it all back, treated it and applied POR15 followed by satin POR15 Top Coat. Not as happy with this as I thought I would be given the price of all the stuff but it'll do okay for now.

kpi1jz


9qi1jz


7ri1jz


The aluminum floor had some awful sticky covering on it which was a nightmare to get off but it was all removed and I decided to treat the floor with POR15 bedliner, not entirely convinced on this but I'll see how it goes. The bulkhead and tunnel also got a coat of paint to freshen it up.

cvi1jz


h2i1jz


I then made all new brake lines - the front needed done anyway as previously it had two lines going to each front wheel but now I have one line up to the front and then split out to each wheel. While going this far I decided it would be foolish not to replace the line going to the rear as well. I used copper-nickel brake pipe throughout. Seeing as I had get the accelator and clutch to worth with the new pedal box I fitted new cables in the process.

a7i1jz


Oh I almost forgot, when I pulled the clutch cover off the blown up engine I discovered it had a Barnet Billet Spring conversion kit fitted to give a much stronger clutch so I swapped that over onto this engine. This was some what of a bonus as I'd planned to buy one so some money saved there!

4cj1jz


One more update to come, we're almost there now!
 

PaulYDP

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The most recent work has been plumbing for water and oil. The R1 has a water cooled oil cooler as standard seperate to the oil filter, I decided to replace this with a Mocal Thermostat Sandwich plate and external oil cooler. With having the turbo the oil feed had been taken off an adapter on the original oil cooler and so I had to come up with a way of doing this - Mocal also do a billet plate that can fit between the block and the sandwich plate and gives 3 take-offs, I needed at least two (turbo and oil pressure gauge). One thing that wasn't fitted was an oil temperature gauge so I decided I could use the third one for that so I bought a new racetech gauge and sensor.

(Original setup - oil cooler and take-off adapter on the left)
ohj1jz


Only photo I have of the new setup, this was in the middle of plumbing (and yes everything needs a good clean in there!)
7oj1jz


With removing the water cooled oil cooler it meant I had to rework the water pipes as I no longer needed some of them, this lead to me getting a new radiator and replacing all the water hoses and moving the header tank (previously mounted above the turbo) to the bulkhead. Header tank is ordered but hasn't arrived yet. I made up some brackets and got the oil cooler radiator mounted in front of the main radiator and have the hoses all fitted. Not as easy as it sounds as I'm tight for space and had to do a lot of figuring out and moving things to get it all working.

New Radiator and making some oil cooler brackets
0rj1jz


0sj1jz


quj1jz


I've also decided to change the shape of the exhaust to allow me to run a flared panel at the front. Previously it ran too close to the car and so the flared panel wouldn't fit unless I kept the exhaust inside the panel (initial idea as seen in one of the photos in first post). I bought some exhaust bends and made up my own to suit. I tacked it all on the car and pulled it off to finish welding it but haven't done that yet. When I've it finished I have new basalt exhaust wrap sitting to do the headers and the exhaust.

Only photo I have of the new exhaust is from a good while back and its hard to see the difference!
0yj1jz



That's it pretty much up to date! On Wednesday the parts arrived to make a new turbo oil feed line so I got that done the other night. The previous oil feed line went the long way round the engine and was about 1.5m long for some bizarre reason! In comparison the one I just made ended up about 38cm long... I drained the fuel tank of old petrol and a new fuel filter along with some bits to finish water plumbing arrived yesterday. The plans for today are get the plumbing finished and finish welding the exhaust. After that I need to refit the intercooler and pipes and then wait patiently until my new alloy header tank arrives - not sure when it'll get here. When it does it should be a case of adding fluids and trying to start it for the first time! That will be a big moment. I know I've missed a load of other little jobs that I've done along the way but that gives a bit of an account of the journey to date.

My to-do list is still very long so don't expect to see this finished any time soon! (It's not going to be a @slickcell speed build)! I generally only get 4 or 5 hours in the week to work on things so it's not easy to move quickly (I do spend time planning so I can best use my time but it still doesn't always work out as planned!). I'll be focusing on fitting some of the bodywork soon, especially rear section of side panels and the scuttle. I've some re-wiring of the dash to do while I'm there and fit the new oil temperature gauge too. I'll try and keep this updated!
 

slickcell

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S5 3.0 V6
Nice one Paul! Will be good to see this progress. I’ll spin down for a look in the Westie once it’s built - you can take mine for a spin to motivate yourself 😂

Looking forward to seeing what it looks like blue. 😍
 

Nicky

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HiluxSurf
Excellent work, Paul. Great to see you doing it yourself, and being able to improve on so many things.
 

PaulYDP

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Cheers guys.

I’ll never learn younger that’s for sure! As long as I have the right equipment I’m happy to give things ago, if you take your time you can do most things.

I got a number of things done me today but nothing major ticked off the list unfortunately. Exhaust is now all welded up, most of the water hoses are fitted now but I’ve now decided to replace the last few small hoses so can’t tick that off just yet. Heated shielded some wires too, moved the horn to allow me some more room to route wires etc and wired up the fan. All just small stuff but takes time!

135AD6F2-49BD-421F-891C-BBAF2BF1D9FD.jpeg
92176BD5-0D42-4069-A8E6-BEFF9B0B2067.jpeg
 

michelinman

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Thanks for taking the time to put the thread together, the project looks really interesting and fun! I can totally relate to your approach to giving everything a go and I salute you for working through your injury. Subscribed!
 

subie_andy33

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ImprezaSTI
So once I had the cage finished it was on to the next thing that I wasn't keen on, that was the pedal arrangement and the fact the brakes were all off one master cylinder with no easy means of bias adjustment. The pedals themselves looked tired and basic so I treated myself to a Christmas present of a new CompBrake pedal box, it's a nice bit of kit. It took a heck of a lot of cutting to get the old pedals out with not much room for getting a grinder in but I got there and got the new pedal box in.

(I appear to have no photos of the originals but safe to say it was basic....)
iei1jz


vfi1jz



Next I rubbed down and painted the chassis. Paint was flaking off all over the place so I sanded it all back, treated it and applied POR15 followed by satin POR15 Top Coat. Not as happy with this as I thought I would be given the price of all the stuff but it'll do okay for now.

kpi1jz


9qi1jz


7ri1jz


The aluminum floor had some awful sticky covering on it which was a nightmare to get off but it was all removed and I decided to treat the floor with POR15 bedliner, not entirely convinced on this but I'll see how it goes. The bulkhead and tunnel also got a coat of paint to freshen it up.

cvi1jz


h2i1jz


I then made all new brake lines - the front needed done anyway as previously it had two lines going to each front wheel but now I have one line up to the front and then split out to each wheel. While going this far I decided it would be foolish not to replace the line going to the rear as well. I used copper-nickel brake pipe throughout. Seeing as I had get the accelator and clutch to worth with the new pedal box I fitted new cables in the process.

a7i1jz


Oh I almost forgot, when I pulled the clutch cover off the blown up engine I discovered it had a Barnet Billet Spring conversion kit fitted to give a much stronger clutch so I swapped that over onto this engine. This was some what of a bonus as I'd planned to buy one so some money saved there!

4cj1jz


One more update to come, we're almost there now!
Awesome project. Look forward to watching the updates! :grinning:

If you don't mind me asking, why were you not totally convinced with POR15? Have heard a lot of good things and was planning to get enough to do two cars.
 

PaulYDP

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Cheers for the comments.

As for POR15, if you are using it on steel that's already has surface rust then it's great - it really takes well and gives a good solid finish. If however the metal is "as new" which in why case it was when the old paint was removed then it really didn't key very well and I followed the instructions, used their degreaser and metal prep etc. What I've found is that it's been reasonably easy to mark it which wasn't what I was expecting! On any areas that I used it that had a bit of surface rust though as it really seems to soak in to those and it's noticably different.
 

PaulYDP

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Not much in the way of updates but did get an hour or two in the garage this week. All just small stuff to get ready for some bigger updates.

Got some of the wiring striped back ready to tidy and reroute and did some planning of that, fit intercooler set up and worked out mounting that also. Frustratingly I’m waiting on things arriving to finish both the fuel and coolant side of things, really hoping they arrive tomorrow and I can leave it ready to turn over...

One big part of the coolant puzzle did arrive today however, my new made to order header tank - nice bit fit work!

8AD54231-5110-4BB6-ABCF-0C70529F8FE5.jpeg
 

gixermark

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great thread Paul... sorry to hear you’ve been having wrist issues... hope that’s behind you.

you are getting on really well! Just highlights to me how utterly useless I am at building/maintaining/modifying....

The car will be a weapon when sorted... if it’s running sensible boost should be grand. Nice work on the preventative stuff - oil cooler/temp gauge/clutch etc. Pedals look ace.

if anyone deserves a decent run in a kit car it’s you! hope you get her running for spring
 

PaulYDP

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PaulYDP
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Oh, weld porn! Is that a standard of the shelf unit from that company, or did they make it specially for you?
It’s an off the shelf unit designed for a Westfield but they make them to order in most cases. They do a lot of custom work too. It’s nice, the cap is engraved and stuff but never took a photo of that!!

Cheers Mark, wrist is heading the right way and not holding me back now! Nothing I’m doing is too special or going to win awards but I’m enjoying doing it myself and that’s the main thing for me!

Today saw me get all the coolant side of things finished, coolant bought and ready to fill. Fuel side also finished with all hoses replaced and new filter, glad I did this as I found a split in one!
Got the diff drained of oil and new oil bought but not filled. Also new spark plugs also got today but again not fitted yet.

Started making brackets for the intercooler, one made and welded on, the other made and just needs welded but ran out of time. Discovered today the battery is completely goosed so need a new one, crank time is getting closer though!
 

gixermark

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Jack Webb motorsport do lithium if that’s the route you are taking...

Superb progress.... I need some of your energy and enthusiasm!
 

PaulYDP

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Jack Webb motorsport do lithium if that’s the route you are taking...

Superb progress.... I need some of your energy and enthusiasm!

Ah good stuff, I’ll check them out and see. Had looked at lithium ones early for the lightness factor!

I’ve went through the motions of no enthusiasm before but really back into it now and every bit of progress keeps me motivated!
 

slickcell

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Ah good stuff, I’ll check them out and see. Had looked at lithium ones early for the lightness factor!

I’ve went through the motions of no enthusiasm before but really back into it now and every bit of progress keeps me motivated!

good to hear you’re motivated to finish it! I can’t wait to hear it starting! I’ve been working like mad lately (6 days a week) so haven’t had a chance to do anything on my car. I’m off Wednesday and Thursday though so I’m planning to get my engine rebuild started 🤟🤟
 

PaulYDP

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Motivation is good at the minute, long may it continue! Aside from a battery I don’t need to buy anything else to get it started so it shouldn’t be to long...

Hateful when work gets in the way lol! Hopefully you can make a good dent in it this week.
 

michelinman

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Motivation is good at the minute, long may it continue! Aside from a battery I don’t need to buy anything else to get it started so it shouldn’t be to long...

Hateful when work gets in the way lol! Hopefully you can make a good dent in it this week.

I know that feeling all too well :laughing: Sometimes in work, I think to myself that I could have been so much more productive in the garage, instead of having to deal with fools all day :laughing:

Looking forward to your next update, keep the motivation going!
 
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