Delivery of Full Race Cage

Yesterday my full race cage arrived.  This was delivered on a pallet direct from the manufacturers Caged Laser Engerineering.  It is comprised of a braced roll over bar with the main part of the cage bolting to this and the side chassis rails.

It is very substantial and quite heavy.  Much tougher than the chassis by the looks of it.  Which I suppose is reassuring and whole point of fitting the cage.  The quality is very good and it comes complete with a fixing kit.  We'll see how straightforward it is to install.

Holes need to be cut in the top of the rear tub to allow the diagonal braces to pass through.  The feet are bolted on after passing through the braces through the holes.  This helps keep the holes as small as possible.

I've made a cardboard template to establish the location of the holes.

I'll use this template to transfer the dimensions across to the top  of the rear tub.  I am praying that fuel filler is not in the way and does not need to be moved.  Once I've got the old roll over bar off, and the template offered up, I'll know for sure.

Fuel Filler and Tank Vent Valve

To comply with IVA requirements the cap needs to be tethered to the fuel filler itself.  I copied the idea from the Carbuilder Solutions Catalogue, i.e. brass picture frame wire and cut down crimp terminals.

The cap did need dismantling first, but at least there are two holes available to take the wire and a handy recess to hide the crimp connector in.

With the cap reassembled ready for installation on the car.

Fuel filler hose connected up and all mounting bolts tightened.

I was a bit worried that the two bends required might be too tight or that the pipe might foul on the boot box molding altogether.  In the end it does not seem too bad and all being well the fuel will flow easily down the filler pipe and the air back up.

Next, time to fit the (not cheap at all) fuel tank vent valve.  This allows air in to the tank as fuel is used.  It also allows air in or out of the tank for expansion/contraction due to temperature changes.  Most importantly it does not let fuel flow out when inverted, i.e. when the car is upside down after an accident.  I think this is all done by a clever arrangement of two ball bearings and probably a spring or two.  The valve has to be fitted with the rubber o-ring uppermost.

That's the fuel system complete and ready for service.  Just need to complete the exhaust before the first engine start can be attempted.

Fitting the Main Body Tub

Before the main body tub will sit down on the chassis a hole needs cutting for the steering column and the unused Sierra pedal box mounting brackets need to be cut off.  Some Hammerite was applied to the bare metal to prevent rusting later.

The lower part of the dash (only used during lay up of the fibreglass) needed to be trimmed off. The front edge of the front body sides were trimmed equal and vertical.  The body would now sit down on the chassis.  It is a very tight fit.  It seemed easiest to 'hook' the body under the rear chassis and then pull it down forwards.  There was a lot of creaking from the fibreglass, but it seems I got away with it, without any permanent damage.  Large head rivets were then added under the chassis rear and sides, as well as the top rails under the bonnet.

Couldn't resist cutting a hole for the shiny aero fuel filler and trialing the steering wheel.