Tidying area where side panels meet rear panel

Back in the garage after a weeks holiday so got on with a couple of small jobs.  First job was the trim on the mirror bracket.  I removed the small sections of larger edge trim I had cut and put in place and replaced with the smallter type which I stuck on with Sikaflex.  The bracket should be ok for IVA now.

Next job was to tidy up the area where side panels meet rear panel.  There is a sharp edge at the back of the side panel and the joint needs protecting as it is quite sharp as it is.

I cut two lengths of the interior aluminium trim that I had spare and rounded the edges with the file.  These were the drilled and fixed to the side panel ensuring that the trim covered the joint between fibreglass panels.  I also carbon wrapped these pieces so they are the same as the interior of the car.

Under dash panels

I decided to install a couple of panels under the dash on both drivers and passengers side to hide any sharp edges from the kill switch or the steering column.  I cut two pieces of 0.9mm aluminium to size, approx 320x400mm, and drilled two holes for mounting underneath the bulkhead steel.

This was awkward and I needed to remove the fibreglass bulkhead to get access.  Also marking, centre punching, drilling and installing rivets upside down is pretty tricky and I had to use a mirror to see what I was doing.

I stuck some edge trim on the sides of these panels and also on the bottom edge of the dash.  The finished result looks tidier and will be better for the IVA.  I may get the two panels powder coated so they blend in better also.

Aluminium panel - edge trimmed and adhesive foam to stop vibration.  The panel is only fixed at one end.  It rests against the underside of the fibreglass and is in tension so it quite secure.

Passenger side

Drivers side before

Drivers side after

Other job today was to change the number plate light as the one I installed had a really sharp edge on the bottom which didn't meet the edge radius requirements.

Reverse motor cover + other small jobs

Main job today after a 3 hour garage tidy up was to make a cover for the reverse motor.  I started with a cardboard template before cutting from 1.0mm aluminium.  The cover was bent to shape, riveted together and secured to the underside of the car with rivnuts.  It doesn't look perfect but it will never be seen.  I will however get it powder coated black so it blends in better.

Next I made my reflectors IVA ok by taking the sharp edges out using sikaflex.  I also did the same to the front indicators where there was a sharp edge before the extension pieces.

I also tested a couple of positions for the wing mirrors and I think I have found a suitable position.  I plan to mount them about 230mm above the chassis side bars which, at first glance, appears to give adequate vision over the rear arches.

Final job was to start carbon wrapping the interior aluminium edge trim.  Only done one bit so far, will continue tomorrow.

Steering

Today I put the steering back together after I installed the lock restrictors the other week.  I counted revolutions from full lock to full lock, about 2 2/3 I think, halved this and turned the steering rack to centre.  I marked this position so I could install the steering wheel centrally.

I have got a quick release for the steering wheel but I have read about these not being acceptable at IVA so made the decision to disable the quick release.  To do this I opened up the mechanism and installed an M5 rivnut within the spring which stops the button pressing in.  I then had to assemble it when in position on the steering column and bolt everything on in order.  Next I installed the track rod extensions and ends to the steering rack and got the wheels pointing as straight as I could.  The steering will need setting up properly before I go on the road.

Disassembled quick release and put rivnut in the spring

Collapsable boss installed

All complete

Boot panel complete

I got the boot panel back from the powder coaters today.  There is a small defect in the powder coat, annoyingly it is on the top of the middle piece so couldn't be in a worse place but it will have to do.

Need to sort out how to tidy up the area where boot panel, rear panel and side panel meet.

Also today I installed toggle switch guards to the reverse arming switch on the dash.

Final job was to remake the locking clips for the front indicators.  These cheap indicators came with plastic clips that hold the casing onto the bulb but both of these broke.  I remade from aluminium angle and cut, drilled, ground and filed until they fitted.

Boot panel continued

I continued with the boot panel today.  I marked out and drilled for all the fixings, and them transfered these marks to the fibreglass rear panel.  The rear panel was drilled and rivnuts installed.  I will be sending the boot panel sections off to the powder coaters in the week to get the coated in gloss black.

Boot panel

Tonight I cut the boot panel from a sheet of 1.5mmm aluminium using the cardboard template I made yesterday.

This was simply marked out using masking tape, cut with the angle grinder and edges filed smooth by hand.  I used a 75mm hole saw to cut out for the roll cage.

The carbon wrap I have is only 300mm wide which would mean buying some more at 400mm width or having a join so I am going to get them powdercoated in gloss black once I have drilled all the holes for fixing.  

Cycle wings + Steering rack + boot panel

Back in the garage after a week at Glastonbury to do a few small jobs.  First job was the steering rack, which I bought new gaiters for.  These were a universal type from the local motor factors which had an internal diameter of approx 48mm so will slide over the lock restrictors.  I had to strip down the track rod ends and rack extension pieces to install the new gaiters but it was a fairly straightforward job.

Next job was edge trim to the front cycle wings.  This was done as experiment to see if the small edge trim I bought would be suitable.  I installed this by pressing it on and bending around the curves and it seems fairly secure so hopefully wont have to stick on with silicone as others have done.  I also edge trimmed the corners of the cycle wing brackets and secured with cable ties.

I also edge trimmed around the exhaust as I could touch part of the exposed fibreglass edge with the 100mm sphere.

FInal job was to make a cardboard template for the boot panel.  The plan is to make the panel from aluminium and either carbon wrap or powdercoat.  This needs to be cut into three pieces due to the rollcage bars that stick out.