build diary

July 19, 2004:
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

July 23, 2004:
I'll be taking the body panels in for painting before too long, so I'm working on getting all the holes drilled and everything worked out.
Thus I built the stone shields for the rear fenders last night and finished the drilling for the front fenders and mirrors. The nose cone received the final Dzus fastener underneath the radiator so it's ready. That Dzus, by the way, is going to be difficult to reach when the car's on the ground. I think I'll have to make a special little tool for it. Brian and I also started cleaning up the welds on the header today. It'll look nice when we're done!
entry 502

Working out the pattern for the rear fender shields.
entry 503
Rear fender shield in place - but I did the measuring on the left side.
Turns out there's a small difference in the shape of the right fender at the bottom. I'll be able to tweak that easily then round off the corners.
entry 504
An installed mirror.
entry 505
Cleaning up the welds on the header.
By the time I'm done, it will look like a single pipe. The reflections make it look as if I've really cut down the thickness of the pipe!
entry 506

July 26, 2004:
It was a weekend of fine detail work.
Lots and lots of sanding on the fibreglass body parts to prepare them for painting. They're very high quality and needed almost no touching up - except for the two extra holes I drilled in one of the front fenders. Whoops. So that had to be patched. I also spent some time grinding down the welds on the exhaust to make everything look good. The side panels have been cut to clear the exhaust and they're now installed. It's getting very close - the only large jobs left are the painting and the exhaust. Then it's all down to troubleshooting and tweaking.
entry 507

I had to redrill a couple of holes in one fender.
This meant patching the fibreglass.
entry 508
Getting the nose ready for painting.
entry 509
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