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At Last!. I have started on my car ;-) PART 2

Discussion in 'General car Chat' started by pgarner, 18 February 2009.

  1. old-git

    old-git Moderator

    Messages:
    9,010
    From:
    Essex
    Car:
    Elan & Robin Hood
    The experimental master cylinder reservior arrived today. Needed to check that the aluminium used is suitable for welding before buying another two. Cut it down to size and thinned the walls and cap. Original weight 227gms, now weighs 97gms, 31 of which are in the steel fitting so I will make some aluminium ones :) It welded fine so I will order two more. The shortened height will help in fitting them under my legs in the floor. Also saves around 400gms.

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  2. old-git

    old-git Moderator

    Messages:
    9,010
    From:
    Essex
    Car:
    Elan & Robin Hood
    After an hour and a half of sanding and trimming, the boot finally came out! Next job is to tidy the filler up and infill some voids. Then I have to decide on a gap width and set about sanding.

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  3. old-git

    old-git Moderator

    Messages:
    9,010
    From:
    Essex
    Car:
    Elan & Robin Hood
    New pedal box arrived yesterday. Very well built but heavier than claimed. Website says 2.8kg but it is a little over 3.4Kg

    However, there is a lot of scope for lightening so I will attack it over the next couple of weeks.

    Dry fitting box confirmed that it has to be recessed into the floor. I will also see if I can move the bulkhead/wheel well forward 20-30mm.

    [​IMG]

    Modified master cylinder reservoir (shortened and lightened)) fits but was a little high so I reduced length of fitting. Every little helps. I will be replacing them with aluminium ones as soon as my 5/8" die arrives [​IMG]

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    However, there is no guarantee that the reserviors will remain where they are. It depends on how they interact/interfere with my feet.
     
  4. old-git

    old-git Moderator

    Messages:
    9,010
    From:
    Essex
    Car:
    Elan & Robin Hood
    Things don't always go to plan. I was modifying the next two master cylinder reservoirs yesterday. First one went fine and so did the second one until I relaised that I had made it slightly too tall. So back on to the lathe it went. I had to hold it internally in order not to risk damage to the thread but this hadn't been a problem, I just had to be circumspect and gentle with my tool feed. This time, however, I must have got just a little bit too ambitious and twang! it flew out of the jaws and ended up like this. Oh, well, not the end of the world :)

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  5. T9 man

    T9 man TC Pro Founder Moderator

    Messages:
    19,753
    From:
    London, UK
    Car:
    Saab 9-3SS T9
    You be careful now Steve, don't want to see you injured sir.
     
  6. old-git

    old-git Moderator

    Messages:
    9,010
    From:
    Essex
    Car:
    Elan & Robin Hood
    Thank you for your concern Os, but my beautiful face is well protected and the rest of me can look after itself :)
     
  7. stamford

    stamford Pro Tuner

    Messages:
    3,706
    From:
    Hampshire
    Car:
    MG ZS200
    Doesn't take much for something to pick up and throw itself out of the chuck when working with such thin walled parts. That's why it's important to wear safety glasses and good fitting underwear!
     
  8. TCJBOLDIE

    TCJBOLDIE Pro Tuner

    Messages:
    3,524
    From:
    Brisbane
    Car:
    JB Starion
    Sometimes familiarity breeds contempt OR complacency especially when one has done things 100's of times.
    I only had an accident with any power tool, a grinder long after I stopped building.
    Take care Steve as I'm sure all who have followed your epic build want you succeed and set the time for the fastest Elan on the planet.
     
  9. old-git

    old-git Moderator

    Messages:
    9,010
    From:
    Essex
    Car:
    Elan & Robin Hood
    Thanks for your concern. My Dad was an engineer and instilled a healthly respect for machines into me. I wear a full face shield when cutting or grinding. When grinding I also wear safety glasses under the shield as sparks manage to get under even this!
     
    stamford and TCJBOLDIE like this.
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