Recent content by Fred W B

Then put it back the right way up to see how it looks. The forward face of the seat back / firewall bulkhead is not yet finally fitted, pending resolution of the cockpit accommodation

Then I could-turn the chassis over and start working on the floor panels. The floor is 2 mm thickness, all the previously mentioned panels are 1.2 mm.

Got the internal side panels fully fitted

Got some paneling done. On the foremost bulkhead I made things difficult for myself by wanting to close off on the outside face of the chassis framework rather than on the inside. Instead of just one panel across the bulkhead it had to be in sections. All this to save 25 mm of possible pedal...

At some places I want to do an overlap joint so am experimenting with some makeshift tooling to make a panel thickness joggle.

In other news, I had previously bought bolts with suitable grip lengths to suit the suspension attachments. These needed to have the threaded length shortened. Once this was done I had them plated as part of a batch of sundry small parts and other fasteners. 10 kg (22 pounds) total. Back on...

I made these which work very well for me. I prefer the bottom of the chassis at just above knee height, makes working on anything above that very convenient without bending over .

In some places I am riveting 19 x 19 extruded angle to the chassis to give me a flange to secure to. I figured out a cheat to be able to set rivets at the bottom of a 19 mm U channel with the tooling I have. Just 4 off M4 nuts taped together to make a spacer.

Once I had finished cleaning out all the internal threads I could make a start on the aluminium panelling. Although this is a space frame chassis I want to panel the cockpit internal area so that it resembles a monocoque construction. I intended to fit the floor first but as I turned the chassis...

And finally the roll bar structure. I bolted in the support for the driver head rest just because it could finally be a part that stays on once and for all. First time I have used locking nuts on the project.

Various body mounting and other subframes

A view of the engine bay showing various brackets for such as handbrake cables, fuel tank and lines, brake lines etc . The small structure in the centre of the cockpit that supports the gearshift is slight offset from centre to give the driver more elbow room.

Took some record pictures of the complete chassis. Not shown are 2 diagonal bars that bolt into the front of the side sill structures

Very exciting weekend for me! Got the chassis and subframes back from paint and I am very happy with it. The colour is Basalt grey RAL 7012. Before painting the main chassis and rear section weighed about 119 kg (260 pounds), the zinc rich primer and polyurethane top coat added about 2 kg (4.5...

The garage looks so empty with the chassis gone. I disassembled the build table the chassis has stood on for so long and used some of the material to make a pair of chassis trestles