Parts Painted and Panel Drilling in Earnest

Got the steering rack and column finally painted, ready to re-fit.

Started to drill the tunnel side panels off, using handy drills borrowed from work. I have countersunk the fastener positions under the tunnel top panel, intension is to have 4 locations per panel to fit with rivnuts and bolts. Hopefully this approach will work...

Plan is to get all the drilling done and get the swarf out the way and cleaned up, then get the panels painted ready to rivet at the right time.

Still some to go, around the footwells etc. Hope to get this done soon.





Motivational Visit

Chap from work paid me a visit a few weeks back with a neighbour of his, who has a nice Caterham. Interesting to see the differences, you can see the engineering that has gone into the Caterham on things like the bonnet fit up etc. However, I do prefer some of the Zero features, in comparison.

Update

Been quiet on the blog for a bit, so time for an update.

I've really just been messing around with the steering column, tidying it up and lining it up with the rack.
I also have a compressor and some drilling equipment so I can get on shortly with the panel drilling shortly.
Other parts for the car I now have include the front hubs and carbs (from a ZX-6R).

Steering column brkt bent to the right orientation to allow smooth operation of the bush at the forward footwell bulkhead. Column clamped until I get the right bolts to fix finally.

Steering column ready to spruce up with spray paint.....

And after primer coat.....

Also primed the steering rack ends ready to paint black. I know these get covered later but this will stop corrosion.

Hoprfully get started on drilling off interior tomorrow.......or start on the scuttle.....

Back at Base

Having got the chassis and the rest of the kit in place either in the garage, or the house...its time to get started.....
I have started by getting all the aluminium panels de-burred, as the laser cutting process seems to have left some sharp edges etc. I'll have to do the same with the stainless ones too. They all seem to fit up ok, with a slight angle bend required here and there to sit flat on the square section tubes of the chassis.
Looks like I'll need to get a differential soon, as this seems to be a good starting point for most including GBS.
See chassis in garage on tressles in photos below.....panels only resting on chassis at this stage.....

Pick Up Day - June 21st

After a very early start at 0515hrs and a steady trek down the M74, A66 and A1, I arrived at GBS around 1030hrs.
The guys were very busy, which is good to see and I had a browse around the workshop to get some more hints, ideas etc.
Having taken the engine and gearbox down with me, Richard arranged for me to take these over to the welding/fitting shop to try them on a chassis to see how things were going to fit up, and also knock up some engine and gearbox mountings. See photos below.

All looks pretty good, with only a couple of issues which look like they'll need to be dealt with.
Looks like I'll have to sort out a different gear linkage than the standard one, due to a foul on the chassis vertical and top tubes. Richard has suggested an option, so hopefully this is not insurmountable.
The standard inlet manifold won't fit, so I'll be going with the motorcycle carb option. GBS can do a manifold to suit.
Also at some point, I'll need to get a prop shaft to suit the FIAT gearbox to a Sierra diff.
Got the van loaded in the afternoon and headed home, getting back around midnight.
See next post for kit in garage......

Ready To Go!

Got the van today, and have loaded the engine parts for measuring up at GBS.Early start tomorrow to get down there by 10am ish... garage pretty much ready too...
Looking forward to it....

Getting Ready

So its nearly time to collect the Zero kit.  Van is hired and I'll be shooting down the M74 this Tuesday the 21st to make some last minute choices and bring the project home.
I've been stripping down the FIAT 1995cc Twin Cam engine which I acquired from a chap in Kincardine earlier this year. This was apparently from a FIAT Argenta, so is one of the later variants of this brilliant engine. One which has won (in one form or another) way more world rally championships than any other and, having had a 1585cc version some years ago, I know how good these power units are.
Hope to have the majority of the engine cleaned and painted (where necessary) prior to Tuesday, leaving just the ancillary stuff to buff up and re-fit.
See pics showing the engine when bought and clean-up progress....Halfords engine paint and some thinners being the main ingredients here.

More to follow soon!