build diary

July 16, 2004:
Well, the fitment of the transmission cover is worse than I had expected.
It's really not acceptable and looks quite crude. It's a real pity as it will be very obvious to anyone who looks into the car. Since it's the third one CMC shipped to me (although only the second to arrive), it looks like the only way I'll get one to fit will be to make my own. Even if the bends had been in the proper locations the sides of the cover aren't long enough so the program for the plasma cutter isn't right. This is a bit odd - some of the other panels such as the side body panels and the rear bulkhead are spot on. Still, it'll keep stray hands from getting caught in the driveshaft so it will perform the function for the time being.

I spent most of last night fitting body parts. Both rear fenders are on the car and look good. I did have to flex the fibreglass a little to get the proper curvature - hopefully with good attachment this won't result in stress cracks in the future. The rear fenders are nicely placed over the wheels. Now I can put my taillights in. The front fender stays are also finished although I need to check the lateral alignment of one side. As a last project, I also pulled out my good nose cone and installed the Dzus fasteners that will attach it to the frame. The newer nose is heavier than the original one I was sent - it's definitely stronger. I've put one Dzus on each rear corner of the nose and one will go underneath behind the radiator. The car is starting to look pretty cool in my garage now. Maybe that's why I put so many photos up today - 20 of them!
entry 454

The first version of the header tubes, put together on a tubing bender.
entry 455
Pipe bender versus mandrel bend.
entry 456
The collection of parts to make my own exhaust system.
entry 457
Measuring the bent welding rod against a u-bend to get an idea of how many u's I will need.
entry 458
While my muffler looks like a glass pack from the outside, it's actually a real muffler.
entry 459
The transmission cover doesn't fit very well at all.
entry 460
The passenger side of the transmission cover doesn't even reach down to the bottom tube for the transmission tunnel.
The only places it can be attached are where there are upright tubes.
entry 461
While the rear half of the transmission cover is not visible when the seats are installed, this area is.
entry 462
This is the best alignment I could manage for the aluminum panels on the passenger's side.
It's also very visible once the car is completed.
entry 463
By comparison to the transmission tunnel, here is the fitment of the side body panels.
This seam is so tight it doesn't need any rivets.
entry 464
The rear bulkhead panel was almost perfectly shaped.
entry 465
There's a hole drilled in this plate that's right where I wanted to put a bolt to hold on the rear fender.
I suspect the hole is left over from the original Locost frame design, as this is a shock mount in that setup. The bolt hole I had to drill didn't have much room for error. The unoccupied 1/4" hole is inaccessible from the other side - whoops.
entry 466
The first rear fender in place.
You can also see the fitment of the transmission cover here.
entry 467
Marking out the location for the taillights.
It's a good thing I had a level or these would have been far off!
entry 468
The front fenders in place.
These will cover a 205 tire but the offset needs to be correct.
entry 469
Using a nibbler to create the holes for the console switches.
This was much easier than I had feared.
entry 470
All controls in place!
In front of the gearshift from left: Ignition, starter button, hazard lights. Behind the shifter, turn indicator, headlights, high/low switch and brake bias adjuster. The piece of tape marks out one of the crossbars in the transmission tunnel.
entry 471
Installing the Dzus fastener for the nose cone.
First, drill a hole through both parts so that the end result is aligned.
entry 472
The Dzus fastener temporarily held in place.
The countersunk hole gets quite close to the trailing edge of the nose cone. This recessed lip on the nose really could be 1/2" longer to make this easier to fit.
entry 473
The Dzus spring is riveted in place.
entry 474
<< | show individual entries | >>