New Project Update 10th July 2003

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Update10th July 2003

The panels are back from the powder coaters, now looking good in matt black. They were given a phosphate wash, an oven dry then a powder coat. Some of the panels have been fitted to the chassis with silicon sealer and rivets. The rivets are special all stainless and the back side bulbs up to give a good surface area. (photo next time) They were not cheap at over £60 per 1,000 (thats 6 pence per rivet!!)

The wiring is laid in the chassis ready for attaching with P clips, the petrol tank assembled and Robin is about to spray the rear wings, so they can go to the laminators with the front wings.

I have spent the last two weeks building an engine for Robin`s Lancia. Next jobs on the car are to attach all the wiring and pipes, fit the fuel tank, fit the pedals and make the hard brake lines.

There are 19 pictures on this page, posted 10th July 2003

Front Wing

The finished front wing ready for a mould to be made. The arch
is further forward and higher with a lip.

 

Front Wing Detail

A small lip is on the wheel arch. This will increase tyre clearance
and strengthen the panel.

 

The Rear Wing In Filler

This is the rear wing in filler during a trial fit onto the body.


Rear Wing Trial Fit.

Another shot of the wing, hopefully it will not look modified.


The Wiring Looms.

These are the two wiring looms that I made. The one on the left is for the engine
management and the right the cars general electrics.

 

Petrol Tank Spill Tray

Motorsport rules say that if the car has an internal filler then
a spill collector which drains to outside the car should be fitted.
This is mine made from stainless.

 

Spill Collector Drain.

I turned up a small boss to take a hose and welded it into the corner.

 

The Petrol Tank In Position.

The spill collector fits well into the chassis opening.

 

The fuel Return For The Petrol Tank.

This is the return into the fuel tank. It was one of the first items to be
put into / onto the tank during assembly.

 

The Two Low Pressure Pumps.

The two low pressure fuel pumps mount onto towers in each corner. These are the next items to go
into the fuel tank. Note the foam cut into pieces and marked up in the background.

 

Low Pressure Pump Detail.

The low pressure pumps mount onto alloy towers. The alloy towers are bonded together
with petrol resistant adhesive. The pumps attach with Tywraps and a viton sheet goes
between the pump and mounting. The hose is convoluted teflon. It was very difficult to get a good
seal with this hose on the fitting.

 

The Pumps Fitted In The Tank.

The low pressure pumps fit into each corner.

 

The Foam In The Tank.

Next the foam is squeezed into the tank.

 

The Collector Goes In.

Next the collector is fitted. Getting the pipes from the low pressure
pumps into the collector was difficult.

 

The top plate ready to go on.

The top plate ready to go onto the top of the tank. The design and construction of
the tank was very difficult. In the tank are 3 pumps, a collector tank, foam,a return,
a breather, a gauge, a filler and it all had to fit in through the top plate. It took a lot of thought to
get everything in through the small hole.

 

Petrol Pipe Insulation.

As the petrol pipes run down the inside of the transmission tunnel close to
the gearbox and engine they will be exposed to quite a bit of heat. I have
insulated the pipes with sleeves. These are made from insulating cloth,
woven glass and aluminium foil. My mother stiched up the sleeves for me.

 

Petrol Tank Insulation.

The petrol tank is also insulated with foam. This will also give a little crash
protection.

 

Panelling Around the Petrol Tank.

Panels fittedaround the petrol tank.

 

Foam in the Hydralic Resovoirs

I had some foam left over from the petrol tank so I cut it to fit into
the brake and clutch resovoirs. This will prevent surge of the fluid.

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