New Project Chassis (page 10)

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My motorvation with the car is now high. I can see the end and I am keen to get it done, I am working harder then ever to get it finished. I am very focused and I am spending nearly all my time working on it or thinking about it. Instead of watching TV I will read catalogues and research parts that I require. I am always thinking of what I have to do and what I will require to do it.

Near side front bulkhead.

Near side front bulkhead.

This picture shows the passenger side bulkhead. It again has to be removable and has some funny profiles to clear the exhaust manifold and engine mount.
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I will make a removable panel held in with Dzus fasteners so I can have fast access to the starter motor. i do not want to remove this whole panel just to get at the starter.
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The lip for the gearbox tunnel.
Another view of the gearbox tunnel.

It is quite daunting to be faced with a gearbox and a pair of chassis rails and know I have to make a removable cover and clear items such as the seats and hand brake.
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I started by making a lip that will screw onto the chassis rail with a vertical face which will take the sides of the tunnel.

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Template for the side of the gearbox tunnel.

The finished tunnel.

On the drivers side the gearbox side screws to the lip along the chassis rail. Making the templates again was not easy to get them just right and looking simple.

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The finished tunnel. It is very light and when bolted in position very strong. Cutting the curved holes for the access panels took ages, because I had to file the last bit to get a smooth finish.
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The finished gearbox tunnel.
Detail around the handbrake lever.
Another view of the tunnel. The two access holes near the rear allow access to the prop. shaft and speed sensor for the dash display (this is not fitted yet but I was thinking ahead)
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I was very worried how I would panel around the handbrake lever and get a gaiter on. But it was the same old case that once I got started and thought about it it was not too bad.
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Gearstick gaiter


Panel down the sill to cover the exhaust.
The gaiters came from the scrap yard. I went to the yard and got 6 gaiters and picked the best ones. Its the first time i have been in a yard for years.
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This shows the start of the work on the exhaust cover down the sill. This again has to be removable so the panel is screwed in rarther than rivetted in.
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