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Robin Hood
September
Thursday 1-9-11
Made some hardboard templates for the bonnet internal parts. This is an idea to make some
strengtheners inside the bonnet.Saturday 3-9-11
Wired up the smith's oil sender onto the engine loom. A temporary fit of GBS's plenum chamber
found that the fuel rail was getting in the way. I had to modify the fuel rail
slightly by bending it to clear the plenum.
 Tuesday 6-9-11
No work on car.
Sprayed the grille with black paint.Wednesday 7-9-11
Test fit of the front wheel arches. These need to be bonded in place
so placement is critical.
Thursday 8-9-11
Trip to GBS for the ECU and the GRP dashboard and other bits. Ouch - Around £1000 spent in one day!
Hopefully I can start saving again and soon !. Dash looks ok - needs a lot of
work though to fit instruments and clear the steering column. The ECU software
looks like it will need some careful study.
Friday 9-9-11
Cut out a slot in GRP dash for the steering column. Also cleaned and polished
up the gauge surround to remove the sharp edges.
It may need some more polishing later though.
Saturday 10-9-11
Fitted the rear light clusters to the rear wheel arches.
Fitted the ECU and wiper motor to scuttle (except the wiper arm tubes which will need cutting and flaring.)
Monday 12-9-11
Box of bits arrived. Put the battery cable in that goes from the alternator in towards
the fuse
box. Wire for the wash bottle routed through tunnel together with the
water pipe. Electrical boots fitted to the exposed
connections like the battery, the starter motor and the alternator (IVA
required on the battery at least). Removed the scuttle again. Cut carpet to fit. Stuck non slip tape to
pedals (IVA requirement). Covered 2 tunnel tops in black vinyl. Patched up
the rear tunnel cover to remove a cut out section that was not required.
Insulation tape over original oil switch sender. I'm not happy about this
connection though and tried to source the correct plug from Ford - Ha -
Fat chance ! I may have to get this
changed later, but as it's only the warning light, it could wait.
After all, the smith's sender will tell you the pressure anyway which is
more important.
 Tuesday 13-9-11
Final fixing of battery panel and battery into place.
Fit carpet to back panel and passenger foot wells.
Wednesday 14-9-11
Drilled holes to fit the dashboard. Cut and fit wiper motor tubes and the spring thing
inside the tube.
 Thursday 15-9-11
Fit the scuttle, washer bottle and inlet manifold final fit. Cut the gasket for
the inlet manifold.
Fit the air temperature sender into the hole in the plenum chamber.
 Saturday 17-9-11 (Stafford Kit car show)
Bought a polishing kit, polisher and powder coat machine for final finishing of
the screen pillars and exhaust mount.Sunday 18-9-11
Installed coolant sensor (not wires) into the thermostat housing.Monday 19-9-11
Rewired the ECU coolant sensor and plug. Cut carpet to fit under the seats.
Drilled holes in the windscreen brackets. Powder coated the exhaust bracket with
the new machine. This produced a lovely finish to the part which you can
see here.
Started to shape the windscreen surrounds. Put the seats in the car (temporarily).
Tuesday 20-9-11
More wiring done under the dash board. Pedal box final fitting and the throttle pedal now
fixed in place. Fixed the flasher relay onto the firewall.Wednesday 21-9-11
Car gearbox now oiled up. Rest of the engine oil put into the engine to top up the
required 5 litres. Car taken off the axle stands so that I could clear
the garage
out and sweep the floor.
Two of the bonnet catches now fixed in place.
 Thursday 22-9-11
Car back on the axle stands. Bonnet catches are now all fitted. Cut door trims (Had to polish
out some scratches with polishing kit - worked quite well). Air filter is now fitted and TPS fixed
into place.
The air filter had to be fitted slightly at an angle to clear the horn I
had fitted earlier.
 Friday 23-9-11
Fabricate a bracket for battery master cut off switch out of aluminium
plate.Saturday 24-9-11
Bonnet strengtheners are now bonded into place.
I had thought I would need this to go all the way around inside the bonnet.
In the end I found
that only the centre section is required to give sufficient strength to
the bonnet. Final wiring of the battery master switch in ( and re worked after it didn't
work !)
Started bending and shaping the windscreen pillar uprights. Cut out a hardboard windscreen
(in case I broke the glass during trial fitting).
Started cutting the bonnet hole to fit round the exhaust.
 Monday 26-9-11
Ignition switch now wired up. Problem with the wash wipe - fixed after a call to GBS
explained the problem (blew the fuse though!).
It turns out that the switches were from the estate version so they needed
modifying. Nose cone all drilled ready for the indicators and the
extensions (IVA requirement). Boots for the indicator extensions fashioned
so that the edges are not exposed (IVA requirement). Grille
finally prepped.
STARTER MOTOR TESTED - WORKS!
Tuesday 27-9-11
Wires in for the side indicators. Tested the ECU - Does NOT work in car but test out of car
ok - why?. Got some more information on the looms to try out tomorrow.
 Wednesday 28-9-11
First fit of headlight. Found a fault in the GBS loom. Had to bypass
engine plug as one wire was not crimped properly and was causing the
fault.
 Thursday 29-9-11
Trip to GBS. Picked up another seat runner and the hoops for the weather gear, PVC tubing,
nuts for indicators (metric fine again) and some stainless trim pieces for the
carpet and behind the seats.Friday 30-9-11
No work on car. Fitted mudguards to bike instead. Put the coolant into the engine, slightly
stronger than 33% concentration.
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