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WCA - Build thread 3

By WorldClassAccident · 282 updates · Apr 2013 to Jul 2018

Read the full original thread (with everyone's replies) in the archive →

December 2013

15 Dec 2013, 8:43am Chassis and Body Interior & Trim
I got some from the local Halfords. It is just a stick on strip for less than £10 and you can get it is varying widths from about 4mm - 1cm wide from memory. It is a D shape profile.

When you say you want chr0me to go on the glass but also thin enough to go into the doors, do you mean along the edge of the glass? That will be only a couple of mm and will be a challenge. Also it will keep getting lifted as the door rubbers scrape the egde of the glass. Possibly better painted?

I saw a full chrome surround for my windscreen on a Z3 the other day and thought "Great, saves me wrapping mine" and everything was good until I googled it and saw the prices!
15 Dec 2013, 3:47pm Mechanical Overhaul Chassis and Body Interior & Trim
My achievement today?

I got the car in my garage!!!

It doesn't sound much but it did involve moving 4 bike, 2 dining tables, 9 wheels (4 alloys, 4 wires and a space saver), 2 sets of shelving along with everything on them plus the sauna.

The result is the car crammed in between everything else but with the heater on and the dehumidifier blowing hopefully it will be warm and dry enough to do some interior work.

I am not planning too much at this point but refitting the door panels with new panel clips will stop them flapping when I shut the doors. I think it will be able to carpet over some of the centre console rather than actually removing it all.

It it a single piece from the dashboard to the bit between the seats and I want to keep some of the front end of it. I was originally going to cut it in half but think I can possibly get away with just covering it. Now the car is inside I don't have to wait for the weather every time I want to try something.



There may be some pictures of the interior in the next few days.
15 Dec 2013, 7:04pm Interior & Trim
Previously I have removed the nasty plastic from behind the seats


and fitted the temparay carpet


Now I thgought I would try the nasty plastic between the seats


Unfortunately it is a single piece which connects to the bit of the central console I want to keep. Note, no joins


So get the car carpet onto a convenient cutting table


Lots of cut - try - cut - try


Looks quite neat from some angles


Less so from others


This is unfinished business


Possibly do the whole section when it is done in leather


All temporary so don't get your knickers in a twist yet please. Also stopped part way through as I was getting frustrated and didn't want to cock it up.

Hopefully I will be able to use the bit I end up with after the current round of cutting as a template for a better and neater cut job.

This will still be temporary until the new year when I hope to have a few pennies to spend on the car again. Until then I shall sit, relax and enjoy a Crafty Hen or two (3 for a Fiver at Tesco!)
16 Dec 2013, 6:07pm General Update
manual gearchange boot would look like on your auto stick - I like that idea. I will keep my eye out for one to try
16 Dec 2013, 10:35pm Electrics
Lrc - I will check what the electrics with the button on my knob does. Might just strip off the plastic cladding and se what is underneath. Will mail you if I want your

Cheers
[Edit]
The button on the knob lifts a rod that stops you going out of park or from drive to reverse without pressing it in. Purely mechanical but kind of handy.

I might get a leather knob for the auto and also fit a gaiter from the manual. It will work in exactly the same way as it does at the moment but look like a manual.
18 Dec 2013, 9:13am Mechanical Overhaul Interior & Trim
Hand brake and steering wheel are waiting for the money fairy in the new year

January 2014

2 Jan 2014, 3:16pm Engine Mechanical Overhaul
A couple of little bits done today. The boot lock cover was easy, the gear gaitor not much harder. I like days like today.

A small sprung chroime keyhole cover and a pusher upper mounted inside. I like the neat result.





Start with a black plastic auto box


Prize out the gear surround


The gear knob just needs a 'gentle tug' to remove it. One of the sets of wires goes to the sports gear select switch. I am not sure what the other wire went to as it 'fell off' but everything still seems to work


I will need to resite the sports select button when I fit the gaitor so lets make a nice tape template and cut it out from underneath so I know exactly how bit the hole has to be



Carefully position it so the switch will be on the side of the drive tunnel near the drivers knee. Carefully cut out the hole for the switch using the template you so carefully prepared. Slide the switch into the perfectly sized hole and discover a metal strut blocking the position. Swear profusely


Make the hole a bit wider so the switch misses the hole, fit the switch and pretend that no-one will ever look there anyway so it doesn't matter


Fit the leather gaiter over the original plastic. Repeat half a dozen times as it keeps popping off at the corners and then fit in place


Smile at the finished job when you see the switch doesn;t really show too much but frown a bit at how stretched the gaiter looks when the stick is in Park. Need to get a better looking knob as well (insert your own joke here)
2 Jan 2014, 6:01pm Mechanical Overhaul Chassis and Body
I had a 'popper' kit that was meant to pull the door opening mechanism and then the popper pushed the door open. They a popular with the custom car boys who want to remove external door handles.

It is just a bolt it a tube with a rubber tip and a spring at the bottom of the tube pushing it up. Shut the boot and the spring is compressed but held there by the boot catch. Release the catch and the boot lid pops up enough to get your fingers under. Quite neat I thought compared to a t-handle or similar.
4 Jan 2014, 6:12pm Mechanical Overhaul Chassis and Body
Picked up the new side repeaters from Hendy Ford. Apparently they had had then for a few days but didn't bother to contact me as they knew I would turn up for them sooner or later. Top customer (dis)service.

Anyway, first place the new units


Then drill a hole to take the push fit units. Does anyone know how I managed to drill a triangular hole?


Make sure the units are a tight fit as there are no clips holding them in place. The BMW units had little metal spring clips but it appears Ford don't bother.
Beneath the black tape is a piece of packing tape reversed to give a smooth surface over the hole left by the old light unit.


Fill the hile behind the tape with body filler and some metal gauze


And when you remove the tape the body filler is almost flush with the outside surface ready for sanding


Quick whizz over witht he electric mini sander and it is all as smooth as you like


Used a bit of spare metal gauze and filler to replace the broken tab on the front wing where it bolts to the car. Not sure this will last but it is better than the 'nothing' that was there before and easier than getting all glassed up for such a small thing.


No pictures of the wings fitted as it is dark and raining but I think they look better than the first lot I fitted. Nice and small. Funily enough I was walking out of the Ford garage when I spotted that Fiat 500 has even smaller and slightly oval clear side repeaters.
18 Jan 2014, 6:47pm Mechanical Overhaul Chassis and Body Interior & Trim
Today I got the car back from Tribute after gettin the door handles changed, side sills put on and brake cooling ducts put in the front. Thanks Chris for the great work again.

My plan for tomorrow is concrete in the remaining three fence posts and then play car.

I am getting some 5" semi riding aluminium ducting to feed cool air from the front of the car to blow over the front discs. It would be a lot easier if the bonnet, with the holes in, didn't lift up at the front. As it is I will need to have one bit of ducting connected to the bonnet and another piece pointing at the brakes and some amazing luck to ensure they line up when the bonnet is closed.

The other good news is that after getting rid of the sauna from the garage there is now room to park the car inside with both doors open and walk around it. I couldn't believe the luxury of sitting on some dense foam matting in the dry with the electric patio heater keeping me warm while I fiddled with the front wing to get all the bolts correctly attached.

I also managed to rescue my chrome filler cap which appeared to react really badly to uk weather by developing both pitting and crusty layers. A short whole with a polishing wheel fitted to the Dremel and a bit of chrome cleaner sorted that out.

I didn't get much else done today as I turned the 1 hour journey back from Chris into a 3 hour maximum attack, roof down, traction control off session of pure enjoyment. Wet roads and no one around is great. Drifting the car at legal speeds with clear visibility. What fun!

Anyway, relaxing in a bath with a couple of Old Crafty Hen (beer not women) and thinking about the Tribute Owners Club.
19 Jan 2014, 9:36pm Mechanical Overhaul Chassis and Body
No paint, too much time enjoying it!

Handles make me smile each time I open the door.

Refitted the door cards today but wasn't able to do the brake vents as I couldn't get any aluminium ducting in 5 inch. B&Q reckon they should have some in mid week.

Need to see what the money fairy brings me at the end of the month before I decide whether to paint it up myself. I have one pressing debug to pay before I. Other with paint and powder coated wheels.

Hopefully it will be a birthday present for me in February.
20 Jan 2014, 12:15pm Chassis and Body
Not sure how thety fit as I got Chris to do that.

They do look amazing, taken from a Fiat Barchetta. Your thumb presses the button and the metal bar pops out for you to pull on.

The metal bar is a lovely shaped and rounded piece of aluminium that is a tactile pleasure to touch. Makes me smile when I open the door each time.
20 Jan 2014, 10:17pm General Update
Agree about the sills. They looked like a great idea when we first saw then but they just don't work.

Glad you like the handles too
21 Jan 2014, 3:58pm Engine Mechanical Overhaul Chassis and Body Interior & Trim
Are you sick and tired of Scottie's carefully presented threads with detailed photographs of how to tackle any task and complete it with a first class engineering solution?

Me neither but here is a thread that is almost the complete opposite of Scottie's threads. It shows how I painted my car after the latest changes Chris has made.

First you need to gather all of the tools and materials required:
Masking tape - for taping plastic bags
Plastic bags - for masking the bodywork
Scalpel - For cutting up the bags
Heat Gun - For heating up the tape so it would unroll and stick - It was very cold in the garage
Axe - Well, it is always handy to have an axe there



Start taping the car up to cover anything you don't want to go red. Decide to turn on the patio heater - I mentioned it was cold. Always make sure you are painting in a proper well ventelated booth with no sources for dust or dirt.



It is important that all bright work is protected such as the beautiful new handles and the petrol filler cap. Paper plates are about the same size as fuel fillers.


The ambient temperature affects the paint characteristics so ensure your paint is warm, or at least liquid, before you start. I told you it was cold.


Before you start any of this make sure the entire car has been properly cleaned. Do not just plonk it in the garage after driving back from Dorchester on wet and muddy roads. You did read this step before you started didn't you? No? Oh well, you can either untape it all, take it outside and wash it properly or run a couple of baby wipes over it.


Here is the fully masked off car ready for painting. Please don't look where the side repeater used to be. Definitely nothing to look at there. We can always look at that bit later.


Mixing paint is a fine art requiring the exact proportions of paint and thinners. Remember that paint stored in nearly empty tins can evaporate slightly and that the ambient temperatures will affect the mix.


Adjusting for ambient temperature that looks about right for 'Bastard cold'


Stir well with an old hacksaw blade taking care not to spill it over the edge of the glass and all over your hands.


The first coat doesn't need to be thick but you should try for an even coverage. Well I tried... Notice the garage door is open now. I thought the 'Red Mist' meant getting angry, not getting painted. I can still taste the thinners now


You know that bit we didn't look at earlier? Perhaps we should have, it looks like someone forgot to spray it with any primer. Do you really need primer?


Yes


And here is the finished article. I will wait for the paint to bake under the patio heater for a bit and try to get some 'on the road' pictures tomorrow or Thursday depending on weather and work
21 Jan 2014, 6:20pm Chassis and Body
I think I better point out that I plan to get the car sprayed properly soon otherwise I might have taken more care...

...might
21 Jan 2014, 8:50pm Engine Mechanical Overhaul
Mr Towed - I know you are a policeman but please try to quote the whole statement ;-)

Are you sick and tired of Scottie's carefully presented threads with detailed photographs of how to tackle any task and complete it with a first class engineering solution?

Me neither
21 Jan 2014, 10:13pm Interior & Trim
especially patio heaters

Look closely and you will see it is an electric patio heater. They promise much but are absolute rubbish outside. It was a big waste of money until It starter using it in the garage
22 Jan 2014, 4:49pm Mechanical Overhaul Chassis and Body
Not the greatest phot because the light was fading but you can se the new sills, brake cooling ducts and delicate door handles.

23 Jan 2014, 3:08pm Mechanical Overhaul
Sticky plate on the front. Square on the back. Both black and silver. Show plates only of course with the real ones 'always' displayed when on public roads.

Silver wheels look okay in pictures but in real life they always just looked dirty grey.

I can't afford to get chrome unless someone else wants to pay and to clean them each week ;-)
23 Jan 2014, 5:17pm General Update
Actually my Gangsta Wagon ML is rolling on 20" Chrome, I wonder if they would fit...

Black is what they used when racing so I am staying authentic, nothing to do with being broke.