IVA Re-Test Modifications

IVA re-test booked for 22nd February.  Modifications to address the fail items have now completed.

1.  Exhaust clamp rotated around towards the sill of the car.  Also cut of the excess thread that was showing through the clamp.

2.  Minor wiring change behind the fog light switch so that the switch light only comes on with the fog light iteself.

3.  Brake lining wear inspection holes (13mm) drilled in brake back plates.  New bungs were inserted.  

There aren't too many options for where to drill.  Some of the flat areas are indented for the purpose of holding the shoes in position.  Had to use one of the few spare recesses.

It was quite fortunate that I spent a bit of time working under the rear of the car as I spotted a problem.  I had installed the rear dampers with the adjustment wheel facing up/outwards.  This was okay during the build with the chassis up on axle stands and the suspension hanging.  However, once the car was on the ground and with the suspension moving through its full travel this adjustment wheel was fouling slightly on the horizontal tube of the upper wishbone.  It was lucky I spotted this before any permanent damage was done.

The fix was quite straightforward.  Unbolt the damper top and bottom, spin through 180 degrees so that the adjustment wheel faces downwards/inwards and re-install the bolts.

Exhaust Clamp Tested and Rad Fan Switch Changed

Ran the engine again, this time with the silencer clamped to the cat pipe.  No leaks, so that job is done.

The radiator fan switch supplied by Tiger activates at 84oC.  This is a bit low for the Zetec on fuel injection so I always thought that I'd have to change it over to the higher setting.  Anyway, when I looked at the higher setting it was about 147oC so obviously no use!  I bought a replacement switch (Intermotor 50102 - for Peugeot 205/Citroen BX C15).  The lower setting comes on at 93oC and goes off at 88oC.  The higher setting is 97oC/92oC.  I installed it on the radiator and checked it in operation.  It seems to work okay.

As I have no thermostat installed I need the fan to operate at the correct temperature.  While running the engine with the car stationary the Tiger ali radiator seems to be very efficient at cooling.  I'll have to see how it performs when the engine is working harder on the road.  I may have to watch out for over-cooling, especially in the colder months.

Dashboard

I am using the black GRP dashboard provided by Tiger.  Some people have fixed this on with screws, others with adhesive.  I wanted the clean looks (without screws), but without the permanence of adhesive.  I decided in the end to use regular clear silicon sealant.  My thinking is that it will hold the dashboard firmly, but can be removed later, if needed.  Perhaps by using a very thin long blade.  That technique may damage the dashboard, who knows.  Hopefully I won't need to find out.

I am mounting the digital dash (nearly) flush into the dashboard itself.  A template was cut for the hole required in the dashboard.

Hole cut in dashboard prior to sticking the dashboard to the body shell.

 Same size hole made in the body shell behind the dashboard.

A bracket to hold the digital dash at the right 'depth' was fabricated out of aluminium strip.  This was glued to the back of the dashboard using two healthy blobs of epoxy resin.  Seem to have held very well.

The dashboard had to be filed a bit to get the correct profile to match the scuttle.  I then took a few more millimetres off all round.  This allows a little space around the edge that I will glue some rubber trim on to for IVA.  I've tested a short length, made from the round part of P-trim, and it looks quite smart.

A second bracket was made to brace the lower part of the dashboard - to stop it flapping around.  Once the digital dashboard was mounted the switches were installed for the headlights, etc. Powered up and everything still worked!