Robin Hood Diary October
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Robin Hood October

Saturday 1-10-11

Made the headlight looms and fitted the headlights and tested them. (Note GBS told me incorrect wiring for the 3 pin plug). I cannot check the alignment though (IVA requirement). Powder coated the indicator extensions (IVA requirement) and the grille (over paint). Put heatshrink sleeving on the indicator wiring to the wheel arch and tie wrapped it to the wishbone (IVA requirement). Wired up the TPS and calibrated it to the ECU. Found a flaw/fault with one cycle wing and will need to exchange it the next time I go to GBS.

Monday 3-10-11

Seats finally mounted in the car after making a template from hardboard. Seat belts temporary fitting.  Tried out the steering wheel which will replace the sierra one eventually (IVA requirement to pass test - use an original one NOT airbag though).

Tuesday 4-10-11

ENGINE RUN FOR FIRST TIME! (Insurance now in place)

Wednesday 5-10-11

Applied Wunderseal on the underside of the rear wheel arches. Horrid stuff ! You cannot apply this with a brush, I eventually had to resort to using an old spoon. Car is back on the floor and driven out and in the garage for the first time. I had to remove part of the garage floor as the first time out it caught on the bolts holding the seats in ! I later increased the ride height by adjusting the pre-load on the suspension springs.

Thursday 6-10-11

Dashboard holes drilled for the instruments and the dials fitted into place - need to wire these up. Circlip fitted to hold a 2p piece in place which should have been in place on the gearbox to hold the oil in ! Lambda sensor fitted. Exhaust slots cut to allow the clamp to hold the silencer on and put the silencer in place. Need to install the exhaust support bracket.
 

Friday 7-10-11

Added rubber trim to rear wheel arches. All ready to fit except for the plastic plug head for the wiring which was missing.

 

Saturday 8-10-11

Stamped out the VIN Chassis plate. Put the car back on the axle stands and the handbrake was re-routed and fixed in place to improve the routing. Car driven briefly for a video clip.

 

Sunday 9-10-11

Fitted one stone guard onto one wheel arch.

Monday 10-10-11

Fitted the other stone guard. Ordered a stainless steel catalytic converter and placed an eBay bid for some C spanners so that I can adjust the suspension springs to increase the ride height. Asked about the dashboard electrical plug again from GBS.

Tuesday 11-10-11

Offside front cycle wing permanently mounted. Needs a little more bonding tomorrow. CAT arrived - off to welders to weld into the silencer.

Wednesday 12-10-11

Grr. After I had bonded the front wheel arch I found it fouled on the tyre. I had to cut it off before the sealant become totally solid and remounted the front part of the wing. I will need to check tomorrow if this clears the tyre. Seats and seat belts final fitting (less the carpet - this is in case I have to drive down in the rain for the IVA). Dashboard out yet again. The replacement steering wheel finally fixed to boss ready for after the IVA. Windscreen trimmed ready for powder coating. Fit chassis VIN number and covered the ends with sealant.

Thursday 13-10-11

Forgot to write up this book ! Started back to the book on 23-10-11. Most of the time spent waiting for parts and the other car (Renault). To date: Made a cover for exhaust over lambda sensor and joint.  Polished the windscreen surrounds and powder coated them. Made plywood boot cover. Made up the wiring loom for the dashboard instruments.

Sunday 16-10-11

Varnished some of the boot covers.

Monday 17-10-11

Polishing of the windscreen surrounds ready for painting and powder coating. This has meant that some of this write up has gone out of sync with what happened !

Monday 24-10-11

More work on the boot lid. Fastened most of the bolts under the rear wheel arches. Tidied up a bit.

Tuesday 25-10-11

Being chased by the insurance company for the Registration plate again.

Wednesday 26-10-11 - Sunday 30-10-11

Boot lid now on and some IVA edging round it.  Boot lock arrived and fitted in place.  All the white outer wrapping finally gone. Dashboard is now almost completed. The voltmeter needs replacing as it turned out to be faulty.

Friday 28-10-11

Have now put the label onto the brake reservoir (IVA requirement).Testing out of all the lights now. Started to fabricate the centre console with the switches for the Fog light horn and the accessory socket.

Saturday 29-10-11

Started to pull off the last remaining white protective coverings. Aside from all this building, I need to build a parcel shelf for the other car.  Gone building mad!

Monday 31-10-11

Now off the axle stands and drives in and out garage with no problem. Even managed to get onto the road without fouling the footpath. Re sealed the coolant sensor adaptor to cure a leak which seems to have worked. Door trim now on with the centre mirror and two holes in the scuttle for the wing mirrors. Removing last bit of white coverings now. Boot latch came and was installed here.