Thursday, 20 December 2012

GoPro Mount

Finished work for the holidays and I'm still waiting for the new steering wheel, quick release, modified upper steering column, wind deflectors and rear wheel arch stone guard bead to arrive from Westfield however, the Manfrotto clamp mount arrived for the GoPro and the weather looks good for tomorrow so I ventured out to the garage.

I chose the mount based on posts of the WSCC forum and I'm very impressed with it.  It's very chunky and made of metal so should be more than strong enough. The first thing I realised was that it would have to go to the side of the hi-level rear brake light.

1st Picture 

Also looked for places to fit the build plate that Paul & Joe Bromley made for us - on the scuttle by the VIN Plate seems the most suitable.  Also notice that the front suspension was wet with a slight salty "frost" so will have to clean the car with fresh water before I put it back in the garage - fingers crossed for sun shine and dry roads tomorrow!

Saturday, 1 December 2012

500 miles!

After another frosty night the sun came out and we had a lovely sunny winter's day.  I picked up Myles from bag packing at Tescos - raising money for a Rugby Tour to L'Aquila RFC in Italy - town was devastated by an earth quake in 2009 but Rugby keeps going.  I then washed the car before taking James over to his girlfriend's, via Ilchester to pay my dues for a very good talk & dinner to the Somerset Branch of the Army Benevolent Fund before a final a run out with Tricia which included a stop at Bridge Farm to collect 4-5 Litres of their finest Rugby Supporter's Juice and a stop at the local Audi dealership to look at a EuroBox estate car to transport the children & dogs around in - adjustments to the shock absorbers seem to be good but car bottomed out between Odcome & East Chinook so I might need to raise the ride height by 5mm or so.  On the way home the car tripped the 500 miles mark - my target for the year before lay up for the winter - however, today was such good fun I've decided to keep the car in running throughout the winter - just in case we have days like these!

Saturday, 17 November 2012

Ad Hoc WF Owners Meeting

Tricia and I braved the grey sky and set off to drive a loop through Montacute, Stoke-Sub-Hambdon, Crewkerne, East Chinook, West Coker and back to Yeovil.  All went well although there was slight drizzle as we headed towards Crewkerne and we considered heading back to clear skies when it started to clear. 
Nigel watches on as Tricia attempts to maintain her dignity!

 As we headed towards East Chinook I suggested that we stop off at Bridge Farm
 for some cider in preparation for the Rugby this afternoon.
Barn find!

Much to my surprise Nigel was very interest in the car and as we went towards the shop he diverted to one on the sheds and revealed an early-ish Westfield, Xflow engine and twin 45s.  The car was in need of some TLC but, a summer of constant rain and lots of stay-cationers visiting the farm meant that it had been laid up for over a year.

Another cider purchaser/MX5 driver advised of another Westfield owner who lived in East Chinook so this might be start of a South Somerset Westfield Owner and Traditional Cider Drinkers Club!

Over 450 miles now on the clock and when I got home I went round all the shock absorbers a set them to Front 4 clicks and Rear 8 clicks hopefully I'll get a chance to see if it makes any difference tomorrow when I get back from Bridgewater & Albion RFC.

Friday, 16 November 2012


The car is currently stuck in the garage because the weather has been "changeable". However I've been struck by upgrade-itis and so far have the following:

Alpha D shape s/wheel with quick release - on order from Westfield - including a replacement upper steering column inner - aka unicorn horn!!!!

Quick shift adapter - on order from Burton Power
Carbon Fibre rear wheel arch protectors - ready to fitImmobiliser - ready to fitCycle wing mud flap - ready to fit
GoPro 2 HD - 1st one didn't work - replacement arrived today
I'm also watching out for a half hood - SBFS v Westfield - still not sure but I'm certain that I need one before next summer season.

On a WSCC Forum I saw a recommendation to fit the CW mud flaps with velcro so might try this this weekend.

Saturday, 10 November 2012

Blat Time

The weather looked okay yesterday so I took the car into work for the first time.  Unfortunately the view through the window looked menacing all morning so I decided to take it home at lunchtime.  Brendan was back from Yeovilton so it gave the opportunity for the two of us to have a 1/2 hour blat - his first time in the Westfield since the trip to Bristol for the IVA, we dropped the car in the garage at home and return to work in the Clio.

Just after lunch today James wanted dropping off in town so we got the car out of the garage and took the long way into town after filling up (13.7 ltrs) at the local Asda - I'm now not convinced that the fuel gauge is working as it was still showing full!  After dropping James off I got home and started to investigate a strange metallic banging sound - after rattling various things under the bonnet etc I found a can of 7 Up under the passenger seat left there since Exeter.  When I got inside Tricia had finished the ironing and said she'd like a run out so we did a circle from Yeovil through Mudford, Marston Magna, Queen Camel, Yeovilton, Ilchester and then back to Yeovil just after 2 pm and in time for the England v Fiji Rugby.  By this time the fuel guage had moved from well over full to full so I'm now not sure whether it's working or not?  Total distance now 375 miles.

Friday, 2 November 2012

Side Screens and Fuel Gauge fix

 The weather forecast is for sunny but cold weather and learning from experience I decided it was time to fit the side screens.  It was straight forward enough fit the screens, workout where the straps needed to be a drill a hole in the side screen.  After bolting on the strap mark out where the popper stud needed to be on the inner panel then drill and rivet.  The overall position of the strap has to be as far back as possible but operable from the seat.
Once the side screens were fitted I jacked up the front of the car and spotted the slight oil leak was coming from the sump oil drain plug so I tightened it up and cleaned off the excess.  Then on to the fuel gauge - Mark at Westfield had advised that the most likely cause was a bad connection and sure enough one of the wires was not properly connected so removing and refitting the boot lid and liner took longer than the actual fix.

Total time 1 hr, so total time 236 hrs excluding the day at the IVA.  Then Myles and I went out for a quick blat for half an hour - total distance travelled now 312 miles

Saturday, 27 October 2012

Exeter Kit Car Show

I wasn't certain we would make it as I had a number of tasks to do before I could consider losing 4-5 hours going to Exeter.  The morning got off to a good start, I took the 807 to Quedam Tyres for its MOT and it passed so things were looking good.  Then on to Mike the Barber's, no one was waiting and the customer in the chair was more than halfway through his cut - Myles & I had our hair cut and we were home by just before 10:00.  Allanah had spent the night at a friend's house so there was no dancing taxi service required so - time to go to Exeter.

Mud splattered 1 is mine!!!!!!

The sun was shining but it had been very cold over night with a ground frost so Myles and I wrapped up warm and set off.  After about 10 miles I had to admit that not fitting the side screens was a mistake and Myles looked frozen.  Over about 50 mph the hot air from the heater was completely mixed with the cold air coming into the car, lucky that Tricia had insisted that he wore a hat and gloves.

We arrived at the show at around 11:00 just as the car clocked up 200 miles, after a diversion to the public car parking and then back to the club car parking, we parked up in a row of 7 type cars the majority of which seemed to be Westfields.
Myles immediately went to the Westfield drifting area and after parting with £10 when for a spin - literally - video too big to post on the blog

We then spent a couple of hours walking around the displays - Myles bought a balaclava, a Westfield fleece for the journey back and a BB Gun (don't ask!).  He also identified a couple of options for the next project (in his dreams)

The journey home was uneventful, Myles was very warm under all those new layers and we stopped for petrol: 14.11 ltrs to cover >100 miles so over 30mpg not too bad.  When we got home Tricia suggested the two of us go for a spin so we headed North through Ilchester, then on to the Mackrells before stopping at Heck's Cider Farm in Street.  The FW Boot just about took 4 ltrs of cider, <lb of Cheddar and Stilton cheeses and a jar of pickle.  

On arriving home I cleaned the car that has now covered just less than 300 miles.

Sunday, 21 October 2012

More driving

The weather has been reasonable all weekend and I managed to put another 80 miles on the car.

The shake down problems now include a fuel gauge that stays on full permanently - on the way up Mudford Hill the car started to splutter and James & I just made it to the fuel station on Reckleford Rd as it cut out; took 21.5 litres and restarted without a problem.

The weather forecast looks good for the next week so I plan to get as many miles on the car as possible before laying up for winter and starting to clear the emergent faults.

Friday, 19 October 2012

Registered & 1st Blat

The Blatting Gods were smiling on me today - I got back from a couple of days at Shrivenham and found a letter from the DVLA stating that the Westfield is now registered with the private reg, there was a tax disc attached and a V948 Number Plate Authorisation Certificate which allows the number plates to be made whilst I wait for the V5C to come from Swansea (already had them!). I put 34 miles on the car split between James & Myles - smiles all round and the forecast is no rain tomorrow.

I've already started to log some shake down problems that will need looking at:

(1) All the instruments are fogging up once the heater has been running for a reasonable time.

(2) The steering column - vibration just over idle.

The Cobra Immobiliser arrived in the post and I'm working out how to fit it and the wheel arch protectors

Wednesday, 17 October 2012

Visit to the DVLA

Visited the DVLA in Filton, Bristol and after 40 mins (35 mins of which was waiting) walked away with a scrap of paper confirming that they'd extracted £275 from me and - subject to the paperwork all being in order - they'd post out a taxi disc.  Hopefully it will arrive by the weekend and the sun will come out - or at least the rain go away!

Friday, 12 October 2012

Post IVA Upgrades

Not a lot to cover but Mr Postie delivered some bits today:

First thing was a proper +ive terminal cover for the Battery - a little bit bigger than I was expecting but fulfils the agreement with Howard at the VOSA Test Centre to improve in the future.

Then the rear arch stone guards from CarbonMods - I was worried that they wouldn't fit as when I ordered them I selected the FW body but when the order confirmation came through the description had expanded to include "FIXED ARCH".  James held them against the arches and they look very nice and fitted well (hopefully Tricia won't ask what they cost!) they will need riveting in place - 3.2mm black rivets ordered. 

Scanned and emailed my IAC to Westfield yesterday, hopefully the Certificate of Newness will arrive tomorrow so I can finish off my pack for the DVLA registration on Wednesday.

Wednesday, 10 October 2012


In the queue - naughty number plate!
Not the best of starts - trailer tyre slow puncture/flat followed by the cover being ripped off then traffic and road works conspired to make us 30 minutes late - then met by the inspector who advised that he would be instructing 12 students on the VOSA IVA Inspector Course in the practical aspects of an IVA.........

Things of note - (ie fails that the inspector allowed me to fix!!):

(1) I'd fitted the front number plate with a private number - cars should not be presented with number plates if unregistered (which clearly without an IAC they can't been) - Inspector said he would inspect because the car had been trailered to the centre - no need to unstick it
(2) Exhaust front clamp needed to be turned around to miss the under body "cone"
(3) Self adhesive cable clips not acceptable on external surfaces ie fuel tank for sender cable - ty-wrapped to mounting band

(4) FW Head Light mounting thread needed to be covered - cut end off a 13mm cover, split it and siliconed in place

(5) Battery +ive connector needed to be covered - 10mm(ish) cover fitted - whilst a minimum pass the inspector suggested I might want to look at it again to improve further - (I've ordered proper covers through ebay)

(6) +ive feed to the starter motor needed a cover - luckily I was able to fabricate one with pipe to an acceptable standard as none of my spares fitted

(7) Westfield Tax Disc holder - failed interior sphere test - removed.....

 And in the end - a PASS

The "rule of thumb" test that the inspector applied to the build/fixes was "would a car manufacturer (Ford/BMW/Audi etc) do it, & would you buy it, like that?"

The test started at 08:30 and I was issued the IAC at 15:15 with a 15min coffee break in the morning and 45mins for lunch - managed to get a bacon roll, denied earlier by our tardy arrival, from a burger van down the road from the test centre.

What the collective noun for a group of VOSA IVA Inspectors?
Many thanks to all WSCCers for all the advice and build sites (especially Rhett's and Kevin's), Tigger at Westfield World, Mark Walker at WF for the Speedo Certificate and frequent advice through the build, Bren for transporting and helping work out/fitting the fixes (and on his birthday too) and Howard, the inspector at the VOSA Test Centre, Bristol for talking me through the whole process and giving me advice and time to sort out the fixes.  And finally Tricia who's put up with me for the last 5 months and wasn't looking forward to me coming home with a fail!

Very Happy - just have to get the Registration sorted.

Saturday, 6 October 2012

Emissions Re-test

Having sorted out the Throttle Body balancing and got the start and idle sorted both Mark at Westfield and Guy at Omex suggested it would still be worth getting the emissions tested before the IVA next week.  James and I drove the car down and confirmed the speedo was working - until we got out on the open road and over 40 mph it started jumping around - hopefully this should just need adjustment to the sensor distance from the stud heads.  On to the emissions tests

Fast Idle Test:
CO limit 0.2%vol actual 0.05%vol - Passed
HC limit 200 ppm actual 15ppm  - Passed and
Lambda min 0.97 - max 1.03 actual 1.00  - Passed (phew this was what failed before)

Natural Idle Test:
CO limit 0.3%vol actual 0.02%vol  - Passed

They also confirmed that the new bulb had sorted out the headlight dipped beam shape problem and set the head lights for me.

We went the long way home and worked on bedding in the brakes and confirming the fronts locked before the backs - I think they did and filled up the tank which took ~11 litres despite reading almost full, as the tank is 22 litres it should have been reading half full!

First impressions driving the car were:
Upper wishbone and shock absorber  IVA covers

The front of the car is a long way away
The front cycle wings need mud flaps
I need to watch carefully for and avoid pot holes/raised iron work etc
I need an audio warning or self cancelling indicators
All the instruments have moisture in them

I left the car out in the sun to try and dry out the instruments and allow James to washing it while I picked up Allanah from dancing . The final bits of the IVA kit arrived in the post at lunchtime; the first items I fitted were the covers for the front upper wishbone camber locking nut and after chopping off the tip of the dome and splitting the side these were straight forward to fit with a little silicone to hold them in place.  Unfortunately the second set was not so straight forward and required the removal of the front shock absorbers lower bolt.  While I was doing the n/s I removed completely removed the shock to investigate the problem I had trying to adjust it.  Following Mark Walker's advice to action it through it's full range of action and then try the adjustment worked and I refitted both and torqued up all the bolts with James' help. We also re-adjusted the speedo sensor until the speedo worked but can't check for the >40 mph issue.

Total work today 2.5 hrs for me and 0.5 hr for James - total build/rectification time 235 hrs.

Saturday, 29 September 2012

Pre-IVA Build Finished

While I was in the US a replacement Synchrometer and the front grill arrived in the post.  Unfortunately, whilst I landed at LHR T5 on Tuesday afternoon I'd then had to travel up to Bristol on Wed/Thurs and by Friday all I wanted to do was drink cider and watch the Saints (beat Wasps).  Saturday started with shopping and children taxiing so I didn't get to the garage until 11:00.

First task was to warm up the engine and try to set up the Throttle Bodies with the new synchrometer - success.  I followed the instructions provided by Guy at Omex and also re-watched terryathome's youtube video and initially was a little concerned because although the reading was in single figures it was still nearly twice the 4-5 kg/hr I was supposed to set the induction to.  However, I cracked on and adjusted the idle screw whilst measuring the 2nd intake - I had to reduce the screw setting quite away but as I did the idle improved and I achieved the 4-5 kg/hr required.  By this time the TPS was reading 11, not the ~20 that I'd been told to expect and had originally set the idle to! Next I adjusted the inter-TB screw whilst measuring in take 3 until it matched intake 2 then adjusted the idle by-pass screws for intakes 1 & 4 until all read the same.  (based on this video Spielberg won't have to worry about me as competition)

By now the idle was much better and there were no nasty pops/crackles at idle - success.  I'm also confident that this will have resolved the emissions MoT failure as the adjustments have effectively reduced the air and increased the fuel which is what I needed to do.

Next I refitted the dash and steering wheel and went for a couple of runs up an down the drive to confirm that the speedo sensor wiring and all appeared okay, although @75m there wasn't enough time to confirm accuracy.  Tricia even came out and had her first drive of the car - need to make sure she doesn't get too confident and take over......

Back to the work, Myles and I fitted all the IVA covers to the front suspension, bonnet clips and windscreen pillars.  We used self amalgamating tape to hold the shock and upper wishbone covers - I need to check this is okay. Note: It's not (only classed as a temporary repair) so I replaced with the right size upper WB covers and removed the shocks to fit the covers - however, Bristol Centre inspectors were happy that the shock collet is in the exempt area.

Under the dash I fitted the inner panels, drilling out and replacing one of the side panel rivet and then one more at the front edge.

Then drilled 4 holes in the nose to fit the grill

The final task of the build was to fix the lambda sensor cable with a p-clip.  Again I drilled out an existing rivet and refitted it with the clip.

Build now finished and I'm ready for the IVA on the 10 Oct 12.  I'll take the car down to Quedam Tyres next Saturday to confirm that the emissions are okay and reset the head lights and Brendan has offered to come over and to a trial load to the trailer so there will be no problems on IVA day.

2 hours for me and 1/2 hr each for James & Myles - total build & rectification time to date 232 hrs.

Tuesday, 18 September 2012

Speedo fixed

Myles and I picked up the car from the garage after having it's wheel alignment "MoT retest" and drove home on a slightly longer route to avoid the early evening traffic - twisty country roads and very enjoyable despite the pop pop on throttle off and rattle from the exhaust.  Thanks very much to the guys at Quedam Tyres, Yeovil for doing the alignment - a bunch of real petrol heads who were willing to ballast the car and spend just over a day getting the set up done - I don't think they want to see another WF for a while though!!

Mark Walker from WF provided us the correct wiring for the speedo sensor (and Paul in the IofM confirmed that it was how he & Joe had wired their's):

sensor blue wire > earth
sensor black wire > speedo yellow wire
sensor brown wire > speedo red wire and then > chassis loom green (ign switched power)
speedo green wire not used so insulated with heat shrink

Once we'd done this (and moved the sensor slightly) a spin of the wheel made the speedo needle move up to 10 mph so very happy.

I'm now off the the US for a week and hopefully when I get back the replacement synchrometer will have arrived and I can focus on getting the throttle bodies set up and fitting the covers kit for the IVA on 10 Oct 12.  The guys at Quedam Tyres have offered to re-do the emission tests and head light alignment test just before I head off to Bristol, they also suggested a local (ish) engine specialist who might be able to help with the TB set up.

1.5 hours to re wire the sensor and test the speedo - total build/rectification time now 229 hours

Monday, 17 September 2012

Suspension set up

Car is away having an "MoT retest" and it's suspension set up but the drive down to the garage confirmed that I still have to sort out the speedo although the engine was idling much better.  The synchrometer has gone back to the supplier and they have agreed to send a replacement.

Saturday, 15 September 2012

Alternator change

The alternator arrived first thing this morning with 2 replacement headlight bulbs after finishing my morning/early afternoon children's taxi service I managed to get into the garage by 14:30.

The first task was to replace the alternator - straight forward enough, disconnect the battery, undo 3 bolts and 3 (2+1) wires and then the reverse to refit - access could have been easier but after one hour the job was complete and the ignition lamp illuminated at the 2nd ignition switch position and then went out after engine start; I measured the engine voltage at 13.97V so the battery is now charging.

I then replace the faulty head light bulb, re-wired the n/s head light and refitted it.  Unfortunately once again the bolt slipped around as I tried to finally tighten it.  After removing the main lens and bezel I could see that the tang that I had straightened out yesterday had bend again so I bend it back in place and tried again - after a bit of fiddling I managed to get the tang  in to place so it locked the bolt - the problem seems to be that in order to get the head lights aligned it's pointing too far down and the tang is at the end of/beyond it's effective range.  I looked at the o/s and this was the same so I repositioned it and made sure the tang was engaged.  Tomorrow I'll clear out the end of the garage wall and mark on where the beams should shine and get them set as best I can before going back to the garage.

I checked the fuel tank and there was a very small weep, much less than before, so I tightened the union another half a turn and will look at it again tomorrow.

I exchanged emails with the synchrometer supplier and they have agreed to replace it so I packed it up and dropped into the Post Office whilst on a taxi run this morning.  Hopefully when I get back from the US on the 25 Sept I should be in a position to try setting up the throttle bodies again.

2.5 hours today - total build time now 227.5 hrs

Thursday, 13 September 2012

Head Lights problem solved

Today's priority was getting my day car MoT'd and spending some time with Tricia as it was the last day of my holiday.  The Clio passed it's MoT with no problems, it needed new wiper blades but I had pre-ordered them to be fitted so that was the morning gone.  Tricia and I went into Yeovil looking for shoes and a hand bag - for her obviously - and then went to a small bistro called Mulberry's for lunch which was very acceptable but left me not wanting to do anything in the afternoon.
BAD Bulb
 Whilst not in the best humour for fault finding I eventually got into the garage and started on the head lights - 2 problems - n/s beam shape and the inability to fully tighten them up.  I removed the n/s head light unit and took it apart the tightening problem seemed to be related to a tang that's welded inside the unit that should lock the hollow bolt in place but wasn't so I bent this back into place.  With no obvious problem with the lens I removed the bulb and compared it to the o/s - and they were different. 

From what I saw yesterday the angle that the bulb  was askew broadly equated to the angle that the beam was from the horizontal so I'm confident that this is the cause of the problem - I'll fit a  replacement bulb before taking the car back to the garage for it's suspension set up and ask them to confirm and readjust the head lights again.

Pleased with this first success I decided to look at the speedo to try and solve why it didn't show any speed.  First I checked the sensor, it was slightly too close so I set it to 3mm with is the middle of the tolerance band, testing will have to wait until Saturday.

Now on to the emissions, I'd emailed Mark at WF with a scanned copy of the test results over night so called for his advice.  He believes that the engine is running too lean and suggested that I go through the set up routine again to confirm nothing had moved.  Whilst the hot idle was now reasonable okay the cold idle is very rough and still cuts out unless the engine is rev'd.  Mark suggested I set the overall idle higher to give the Omex more room to make it's idle adjustments.  I went through the routine again but I wasn't confident that I was making any difference and without a synchrometer that I can trust I can't give accurate feedback to Mark.  My synchrometer is now packed up ready to be posted to Mark for him to compare it with the ones in the factory and remark the 4 and 5 kg/hr which is the range that the TBs should be set at.
How not to wire the speedo sensor!
I also discussed the exhaust and steering column rattles with Mark and he said that the factory used lithium grease before installation and that the exhaust shield was the most likely source of the rattle.  I also needed to investigate a problem with the top UJ bolt so I decided to grease up steering column.  On removing the UJ bolt I found that the nut had stripped it's threads so I replaced it however having removed the dash I discovered the speedo sensor earth wire had become detached so I soldered it back on and covered it with heat shrink to provide it with more support.

While I had the dash removed I attempted to tidy up the wiring loom ready to ty-wrap it to the dash support tube once I'm happy everything is working.

Mark also confirmed that my replacement alternator was being shipped today and he'd include a replacement head light bulb, so no need for me to trek down to Halfords tonight.  Hopefully Adrian will also include the front grill and then the car will be fully complete.

2.5 hrs today - total build time now 225 hrs

Note: see post dated 18 Sep 12 for the correct speedo sensor wiring

Wednesday, 12 September 2012


The MoT achieved it's aim, in that it picked up a couple of things that I couldn't have done at home - Lambda emissions too high and, a really strange one, the n/s head light had the wrong shaped beam.  It should be level then divert up to the n/s but it was V shaped.  It has all the same markings as the o/s and is a sealed unit so I'm slightly bemused. 

There were a couple of other items:  Wipers & Washer failed - I'd been using them on the way there so was surprised but the fuse had blown.
Fuel was leaking from the return coupling at the front of the tank.
Front n/s wheel wasn't fully torqued up - oops
In addition to the V beam, the n/s Head light couldn't be fully tightened to hold position.

Just to make my day the multiple starts and lack of a working alternator meant I needs a battery booster to get the car started for the drive home between rain showers.

On the way there I also noticed that the speedo wasn't working, I assume the most likely cause is that the sensor isn't close enough so I'll look at it in the morning.
I've already fixed: (1) the wash/wipe (although one of the blades is very poor and leaves strips on the screen), (2) wheel torque and fingers crossed (3) the fuel leak. The head light looks like you have to press down/pull up on the head light as you tighten because the bolt spins inside the head light.

Luckily I've got a month to sort everything out before the IVA.  With all the messing about there wasn't time to do the wheel alignment so it's booked back in for Saturday and they're going to keep it for a couple of days to give themselves a good run at it.  They did set up the kit and check it and said that it wasn't too bad as nothing was wildly out but every wheel needed some adjustment!!!!!

Tuesday, 11 September 2012

More finishing off

I only managed two hours today just clearing off the final items on the "to-do" list ready for the pre-IVA MoT tomorrow.  First thing was fitting the tax disc holder - rather expensive even with a significant discount - but it should at least slow down someone taking the disc. Note: the disc holder failed the IVA edges test so I had to remove it during the IVA to pass - wait and fit it later

Next was fitting the pedal box cover - I'd removed the carbon fibre wrap as it was starting to lift and didn't look good.  I've ordered some 3M wrap and may try again.  I fitted the cover with M5 rivnuts into the chassis and self tappers into the scuttle and I put 2mm x 10mm neoprene foam around the end to ensure a good seal.

Mark at WF advised that the Westfield/Hi-spec calipers needed the pad dowels cutting down to ~5mm so I got out the dremel and used the cutting disc to achieve it without removing the dowel/pads. After a small slip I used an off cut of ali sheet to protect the caliper.

Given the many electronic gadgets I need to keep charged (mobile, sat nav, ipod etc) I bought a pair of 12V power sockets already mounted on a plastic bracket.  I installed this with a couple of self tappers and took the power from the aux connector on the chassis loom so the power will not need the ignition switch in the I or II position.

Final task was to tidy up the dash wiring and fit the protector around the edge of the scuttle and dash.  At first I couldn't get the passenger side mounting screws covered but after some adjustments I managed to get the lower one covered but the one on the radius remained visible so I painted it black for now.

The final job of the day was to fit the number plates to test the MoT-ability of a stick on front plate.  I fitted the rear plate without the black  "IVA area" plate but drilled it so that I can fit it in the same mounting holes before the IVA.

Total build time 220 hrs.......

Monday, 10 September 2012

1st "Blat" - only down the drive

Mr Postie delivered the upper steering column at lunchtime and thus I was released from "other duties" by Tricia.  Installation of the steering column was straight forward until I got to the electrics - the +12V and the Ignition were oppositely wired between the chassis loom and the ignition switch.  After consulting the wiring scheme confirmed it was the ignition switch that was incorrect and after a quick call to Mark at WF to confirm I swapped the pins over and reconnected.  Note:  The 1st switch position is not used with instruments etc being at position 2.
Unfortunately it began to rain thus no chance of a drive.  While I was on the phone to Mark we discussed the IVA and he advised to fit the  covers to the front shock absorbers - the IVA manual suggests that the area inside the wishbones is excluded from the sharp edges but recent guidance allows examiners to use their gauges. Rather than strip down the suspension I proposed using self-amalgamating tape but Mark said this could be deemed "temporary".  I queried the Westfield/Hi-spec pad pins and Mark said the have to be cut down to 5mm max - Hi-spec had changed the pins without telling WF, so 2 new items added to the "to-do" list. I'd also noticed that the ignition indicator, which I'd noticed flashing on when the engine was rev'd yesterday, wasn't coming on - got the multi-meter out and the power was at the indicator so another call to Mark and he confirmed it was an alternative diode so he's posting out a replacement that should be with me on Wednesday.  I'd put some more fuel in the tank but there was no reading on the gauge so I removed the boot and swapped the wires over and now all is well. By now the weather had cleared up and the drive dried out so I took the opportunity for a quick blat down the drive with Myles who got home from school.

The "run" was repeated 3 more times as various members of the family arrived home. The brakes worked well but need a good bedding in and there's is a ticking sound coming from the exhaust that needs further investigation.  I have the car booked in to a local garage for an MoT and 4 wheel alignment on Wednesday so I'll progress the "to-do" list tomorrow.  Sorted out the insurance for the IVA in Oct and also got cover for the MoT on Wednesday.
3 more hours today so total now 218 hrs.

Saturday, 8 September 2012

Wheels back on and garage tidy

Not too much done today.  First task was to fit the new battery and modify the the top strap.

We started the engine and got it up to full temperature and then set up the Throttle Bodies.  The synchrometer was still over reading but we ignored this and just got the two internal TBs set the same by using the link bar adjuster and once this was done all the TBs were reading the same value so we then when through the idle set up routine.  It's been a painful month or so but I've now got a much better idea of how the Omex Software works to manage idle which might be helpful in the future.

We put the wheels back on to the car and took it outside the garage and set the rear ride height and also cleared out the garage and gave it a good sweep out. 

 Reversing back into the garage the car bottomed out and we determined that it was the rounded hoop below the gearbox so I then got out my concrete cutter and "modified" the garage floor to get some clearance.  I'll repaint in once I know that I've removed enough.

Now ready for next weeks deliveries!!!!

2 hours for James and I - Total build 215 hrs