build diary

May 10, 2004: Lots of work this weekend.
First, driveline angles. I suspect all of CMC's engineering has been done with the smaller 1.6 diff, but even then a mounting point that is about 1" higher would make a big difference. The bottom of the bigger 1.8 differential hits the frame before the diff gets level, and the longer nose of the 1.8 also means the driveshaft is shorter. Thus the driveline angles in my car are now are as good as they can be but still not ideal. The driveshaft angle is a touch under 4 degrees and the diff and transmission output shaft are about 3 degrees out of alignment. I'll see how this works - if there are vibration problems I'll remount the diff higher up in the frame.

I've talked to a couple of engineers about the rear diff mounting as well. They are unanimous in condemming the existing mount for the nose of the diff. I'll have to make a stumpy version of a PPF to fit inside the frame. This could be a bit of a challenge, but it should be worth it in the long run. Lester Seal has the correct idea with his plan to use the PPF.

In other news, I've cut out the bottom of the dash for more legroom. The dash is looking good although my first attempt at some glass to cover the gauges was pretty hideous. I also riveted the rear bulkhead body panel into place - I've been looking forward to doing that for some time! It's the best fitting body panel so far. It needs one small bend at the bottom and two notches needed to be cut out of it, but all the angles appear to be square and it looks good in place.

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