build diary

March 2, 2004:
Surprise surprise, I'm getting tired of wiring.
I'm also waiting for some switches and the circuit breakers. In the meantime, I decided to put in the parking brake assembly. CMC did a nice job of integrating the stock Miata setup into the frame so everything just bolted up. Now I understand the reason for that plate on the side of the transmission tunnel! I might still move the handle a little further forward to tighten the cable as the adjustment is maxed out. It works, but it could work better. The way the plate is welded in, there's not much clearance for the bolt heads without hitting the transmission tunnel cover. I used the Torx bolts that originally attached the top latches to the car for maximum clearance.

Some interesting reading - a Caterham Superlight build. 6 months almost to the day. I wonder if I'll beat that time? There are some entries that make me thirst for more detail:"Fill diff with oil. Cut head, go to casualty."
entry 169

Interesting - the throttle body from the automatic car has some surprising differences.
They're the same basic casting but the machining is different to work with the different TPS.
entry 170
Yes, I'm getting sick of wiring.
So I decided to put in the parking brake. Ignore the wood brake handle. I should have put the mechanism a little further forward to gain a little more adjustment. It does still work.
entry 171
The emergency brake cables hang down a bit below the floor.
entry 172

March 3, 2004:
My headlights have arrived.
They're from a dune buggy shop, and cost $55 for the pair. Of course yesterday I found some listed for $37 a pair but I'm not terribly upset. Part of my wiring order from Del City showed up today as well, so now I can get a little further on the boring work.
entry 173

That's better - no wooden emergency brake handle.
entry 174
My headlights are here!
entry 175

March 4, 2004:
It's almost time for the big Engine Dance.
One motor will get built up, two will get swapped and then the Seven will have a mill. I took the test engine out of the frame last night as it's destined to be made into something special. It was a little disheartening as it looks like I'm going backwards. I've known all along that it was going to come out but still...
entry 176

My throttle body looked a little crusty, so a coat of black paint has fixed that! Why black? Because they're usually bare aluminum and anything short of a full polish will look wrong against the manifold on the engine above.
entry 177
Not your typical "Locost" donor - here's the engine that is destined for my car.
First the block that I've been using for test-fitting needs to be built up, then it will replace my spare engine that is in another Miata, then THAT engine will go into the car in the photo which frees up the 11:1 motor for the Seven. Got that?
entry 178

March 5, 2004:
Had an interesting visit today with a representative of Titan.
They make dry sump kits, suspension parts, steering racks - a good part of what you see in the Pegasus Racing catalog. One of the first parts he pulled out of his truck was a Caterham steering rack. Interestingly enough, it's almost identical in width (measured between the inner pivots on the tie rods) to a stock Miata rack. That means it's about 5.5" wider than my modified one. I need to take a closer look at some Caterham suspension photographs now.

I'm going to be busy this weekend working on a prototype Miata. Don't expect any updates for a while.
entry 179

The steering rack out of a Caterham.
Very pretty, but too wide for me!
entry 180

March 7, 2004:
No, nothing new to report on the Seven.
As I said, I've got a Miata with a prototype supercharger that's taking all my time. But I did discover an error in the guestbook that's been there for a few days. It's working again now - sorry.
entry 181

March 12, 2004:
Okay, time to get back to work.
The supercharged Miata was fun but it's gone now. It did leave behind a nice set of 1999 Miata seats, though. All the wiring bits are here except for my starter button - since I haven't ordered that yet, it's not much of a surprise. This weekend I should be able to finish the wiring once and for all. Of course, we needed a set of rear brakes for a couple of cars in the shop this weekend, so the Seven got cannibalised. Sigh.
entry 182

Aircraft circuit breakers to replace the fuse box.
Thanks Mark! He also included a switch guard that is definitely going on the ignition switch!
entry 183
Caterham supplied a set of taillights.
I was pleasantly surprised by the price - only $43 each, including grommets and a connector. They include a reflector as well as a separate turn light, so legality will not be a problem.
entry 184

March 13, 2004:
Steve at CMC has informed me that they stock the same taillights as Caterham for $30.
Sigh. Well, at least the shipping from Denver was quick and cheap. I had a good talk with the Caterham folks when I was ordering the lights - they're surprisingly interested in what I'm doing. Not what I would have expected, given that I'm basically trying to replicate one of their cars for 20% of the cost.

If you read this regularly, you might have noticed that yesterday's postings were edited. I was frustrated and a little harsh in some of the comments, so they've been expunged. CMC has been having both equipment and staffing problems so they're hard to reach at the moment.
entry 185

March 15, 2004:
It's alive!
Well, not really. But I did some initial testing of the wiring and none of the smoke got out. As any British car enthusiast knows, electrical systems run on smoke. When they break it gets out. The headlights (high and low) work, the turn indicators indicate and the hazard lights flash. I guess that means I now have a really big flashlight on wheels. I didn't check to see if the ECU was reading anything as I didn't want to push my luck. I still have to wire up the instrument panel and switches but that's a quick enough job of just connecting the loose, labelled wires. Everything else looks easy by comparison to this wiring setup! You'll all be glad to know that both the skiing and the mountain biking were excellent this weekend.
entry 186

The circuit breakers are in place.
Oops, drilled an extra hole! I've moved them around a little to make the wiring behind a bit smoother.
entry 187
Doing intial wiring tests.
It might look ugly, but it's pretty much done! I just have to put in the switches and hook up the instruments.
entry 188
The wiring going to the front of the car has been cleaned up.
I'll be using something a little more permanent than masking tape when I'm done, though.
entry 189
One of the boxes of wires that no longer have a purpose.
entry 190
Artsy shot!
entry 191
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