build diary

July 18, 2004:
The #4 runner in place.
entry 477
The #3 runner is done.
I'm not thrilled about a small kink in this one, mostly from an aesthetic point of view.
entry 478
The #2 runner.

entry 479
I decided to move the #2 runner to #1.
I thought I had the ideal routing but this works better.
entry 480
#1 does get a little close to the brake line.
I'll build a shield for this.
entry 481
Cutting and more cutting.
entry 482
The complete header!
entry 483
The only compromise I had to make in length.
About 10mm (3/8") of extra length in the #2 runner. Reaching that position in the collector proved to be very challenging.
entry 484

July 19, 2004:
The exhaust system is complete!
Well, almost. I still have to open up the holes in the flange for the larger 2.5" tube, but then I can start welding everything together permanently. Hopefully without any real distortion! I'm still quite chuffed about how the header turned out - I can see a couple of small changes I'd make now, but nothing that makes it worth reworking. The muffler has been hung beside the driver and I've even managed to put together a tip. Soon enough I'll discover just how loud this thing is! Since a few people have asked, the individual runners for the header will remain individual. The join at the collector is a slip joint. While it will be a little more prone to leaking this will make it possible to remove and replace the header without pulling the engine!

As a short break from all the cutting and welding, I also fitted the tail lights to the car. It's coming together now, and quickly. I'm almost ready to send the body parts off for painting.
entry 485

My heat-shielded brake line.
An aluminum shield plus reflective wrap. This should do the trick.
entry 486
Another view of the header.
entry 487
The complete exhaust system is in place.
entry 488
A change from all the exhaust system photos, here's the rear of the car.
The tails are straight, they just look funky in the photo.
entry 489

July 20, 2004:
In order to put the 1.75" tubes into my modified stock exhaust flange, I had to open up the holes a fair bit.
Now I just have to squash the tubes down and weld them in. Then the entire exhaust will start getting welded together - hopefully without distortion!

To take a break from all the cutting and welding, I wired up the taillights. It's so childish to get excited over flashing turn indicators but that didn't stop me. The brake lights, turns, hazards and tails all work. Now I need a decent looking reverse light and a license plate light. I also have to decide where the plate is going to go - it's big on this little car!
entry 490

A test fit of a +38mm wheel with a 205/50-15 tire.
The tire is pressed up hard against the edge of the bracket for the fender. Some modification would be needed!
entry 491
The stock exhaust flange is opened up to fit the 1.75" tube I'm using.
This needs to be brought down a little once the tube is welded into place - look at the size of the port in the gasket!
entry 492
Taillights are working!
entry 493

July 21, 2004:
Not one of my more successful evenings.
I squashed the header tubes down to fit into the flanges and did a little more tack welding to hold the pipes in place. Then just for fun I decided to start doing the final bead on the tubes - and hit my limitations as a welder. After blowing a few holes in the tubes I decided to hand it over to Brian so he can TIG it. I was not happy with myself. Instead of installing the new mirrors I called it a night and turned my attention elsewhere.

Geoff Davis tells me he is reluctantly having to sell his Seven kit. For some more information, check out my CMC kit for sale page. It's available right now and would be a great opportunity for someone who's interested in doing the same thing I am without the wait for CMC to build a frame.
entry 494

One of the header tubes squashed down into the flange.
entry 495
The mirrors! The hardest part will be mounting them high enough to clear the rear fenders.
entry 496

July 22, 2004:
A very different mood from yesterday.
The exhaust is properly welded up (thanks Brian!) and will receive some final finishing tonight. First we had to install it and then run the car. Much excitement! The car has a very, very deep voice and is a good volume. It's not silent but it should be quite streetable. It's probably similar to my Miata. It's great fun to blip the throttle and see things blow away from the side of the car! There are still some wiring problems to be worked out but that's easy.
entry 497

One of the rubber mounts for the muffler.
I had to weld a tab to the frame for this and a hole will need to be cut in the side panel.
entry 498
The complete exhaust system.
Anyone need some short lengths of pool hose?
entry 499
The fully welded exhaust.
It's not terribly pretty yet but it will be cleaned up.
entry 500
This is the size of the hole that needs to be cut in the front panel.
entry 501
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