27 February 2023 Added JB Weld to all the hinges as they will all need additional holes. I sanded the JB Weld flat, I held the hinge up to the door marked the poision for the hole on the hinge, using the penny washers I want to use. Then I carefully and drilled and tapped the hole for the new screw position on the top hinge. I punched a hole in the gasket, for the new hole. With the door still secured in position, I used the gasket to transfer the new hole position, on to the door and then drilled the hole carefully to avoid hitting the body. I completed the same exercise on the lower hinge. The hinges came supplied with studs, but using them on the door attachment would interfere with the closure so I found some bolts to use instead, shortening where needed. 12 March 2023 The replacement MAP sensor arrived so I hooked it up and tried the engine again, the ECU is seeing the MAP and getting a feed from it but something is still not right. Reached out to some tuners to see if someone could help me but it looks like I will need to make a trek. 18 March 2023 Found that one of the studs on the door had snapped off. IT had snapped flus so I cut a slot with my Dremel so I could unscrew it. Fitted the passenger door hinges. I took all the doors off and lengthened the holes to give me a bit more adjustment. The fit in the aperture nicely but the bottom edge is a little proud so I think I need to pack out the bottom hinge a bit to push it back. I marked out the position for the filler cap, taking care to allow for the mounting ring. I cut out an undersize hole then ground it out to size with a flap wheel. I will need to make something to hold the filler pipe I modified before. I a clamp to hold it to one of the chassis rails should work. It will need to hold it at a slightly different angle. 20 March 2023 Designed a clamp to hold the filler pipe and printed it off on my 3D printer. I made it in 2 halves which will be joined by a bolt so it can swivel and will be secured using tie wraps. 25 March 2023 Redsigned my bonnet badge to make it simpler and the text more chunky, popped into rLab and printed off some vinyl and applied to my new braas blanks. 26 March 2023 I cut down an empty milk bottle to hold the salt water for my etching. I drilled a hole near the edge of the badge and passed some steel wire through it then sealed it up with electricians tape. I put it in the salt waater with a steel cathode and turned on the battery charger and left it to fizz away. I had to replace the steel wire after an hour as it had dissolved due to the electical etching process, so I found some thick plastic covered electrical wire and used that instead. Removed a bottom hinge and padded it out with a second gasket which seemed to line up the door with body nicely but it revealed a problem with the thread I'd cut in the JB Weld which stripped. I don't think it is really up to the job. I decided to try putting in a threaded piece of metal. I thought about bonding a nut in there but decided to use a rivnut instead as it was simple to do. I just had to drill the hole out oversize and cut off the flange on the rivnut and I could epoxy it in place. I decided to do all four hinges. While the glue was curing, I got on with finalising the fuel filler hose. I already had the necessary flexible filler hose so it was a case of cutting the hoses to length based on the position of the modified filler adapter. I then took it all apart, sand blasted the metal section and primed and painted it black. I removed the drivers seat and made a start on templating the last bit of the gearbox tunnel using some cardboard. Quite happy with the general look but it needs a bit more trimming. After about 7 hours of etching I removed the badge, removed the vinyl and cleaned it up. Very happy with the depth of the etching, I plan to fill the etched areas with paint and the sand it back to leave the brass showing through. I've another slightly different design that I want to try too and then I'll paint them both up and see how they look.
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AuthorThis is my first kit car although I've messed about with cars all my life. Archives
November 2023
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