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A fit check of the engine/transaxle discovered a lot of preload at the front and rear engine mounts. Upon measuring the engine location relative to the chassis, I found the engine to be 1/8” off center to the left at the front mount. Also, there was no room to install the lower “C” channel...

Hi Aj, The two beaded stainless radiator coolant line are 1-1/2" diameter and came with the car. I also purchased two 3/4" diameter stainless heater lines (.035" wall thickness). I used the JEGS Performance Products 80083 Tube Bead tool on those.

For the E-Brake Bracket Install Suggested Bolts: M10-1.5, 35mm (4 each, Shoulder Bolt), M10-1.5, 30mm (4 each, Cap Screw) Washers: M10 (2 each for bolts and as needed for spacing) Drill Bit: Size R Tap: M10-1.5 With rotor installed, bolt bracket to e-brake caliper and place over rotor at...

David, thank you for the info. I was using the Astro rivnut tool today in a tight spot and could have use the tool from Pegasus. Time to order this tool.

For the E-Brake Bracket Install Suggested Bolts: M10-1.5, 35mm (4 each, Shoulder Bolt), M10-1.5, 30mm (4 each, Cap Screw) Washers: M10 (2 each for bolts and as needed for spacing) Drill Bit: Size R Tap: M10-1.5 With rotor installed, bolt bracket to e-brake caliper and place over rotor at...

Steve, I used the Marine grade JB Weld. It is supposed to be fuel resistant. I roughed up the tube and fitting surfaces before applying the epoxy. I also purchased the McMaster rivnuts and they worked great.

There is room on each side of the fuel tank and tank cavity. I used ¼” thick by 2” wide High-density polyethylene (HDPE) to fill the gaps and used rivnuts/screws to secure the tank into position.

There’s little room between the fuel tank fittings and the tank cavity therefore I had to use 90 deg elbows. The fuel tank return fitting is 3/8" NPT to -6AN; the supply fitting is a 1/2" NPT to -8AN. I used 3/8" and 1/2" aluminum 5052 tubing to fab the fittings as shown. I sealed the sending...

I decided to cut a hole in the firewall at the fuel tank to run the fuel supply and return lines. I fabricated a panel to support the bulkhead fittings and wiring. I plan to route the A/C lines on the passenger side of the chassis and leave the radiator and heater lines routed under the fuel tank.

The fuel tank is located in the center of the car directly above the radiator and heater coolant lines. Insulation is needed to keep the radiant heat from frying the occupants. I lined the bottom of the fuel tank with Sticky Shield from Heatshield Products and covered the radiator and heater...

The fuel tank sensor was too long for the fuel tank. The folks at Speedhut who make the sensor said to carefully cut/trim the outer and inner tube to the required length. Make sure the spacer between the sensor tubes is still present and secure. I cut mine to ¾” above the tank bottom (taking...

I noticed the rear clip latch pin tab (at the roll bar) is fiberglass with no underlying support. It seems a bit flimsy considering the abuse and speed these cars may be subject to. Before removal of the roll cage, I fabricated and tack welded steel tabs under the fiberglass to add the needed...

I noticed the steering arm fasteners were short of full engagement into arm. I installed longer fasteners and added washers and self-locking nuts. It may be overkill but "when in doubt, make it stout".

After a light sanding and polishing of the upper and lower A-arms, I reassembled the suspension. Correct length fasteners were installed along with custom machined aluminum spacers that allowed removal of a handful of washers. All fasteners were checked for proper torque and as each fastener...

With the chassis back in the garage, I used Lava Shield from Heatshield Products to cover the front of the chassis to reduce the interior heat. The Lava Shield is .025” thick and can be easily cut with scissors or an Exacto knife.

Welcome back Dean! Please keep us posted on the engine issue. My configuration is very much like yours.

The fuel tank return fitting is a 3/8" NPT; the supply is a 1/2" NPT. For clearance, I had to use 90 deg elbows. 3/8" and 1/2" aluminum 5052 tubing was epoxied into the fittings as shown. After the lines were fabricated and the sending unit sealed, I filled the tank with 5 gallons of solvent...

Hi Steve, Welcome to the family! Like Mark, I drilled into the web and machined spacers to center the emergency brake caliper over the rotor.

Mark, love the look of the contoured wire mesh grills. Thanks for posting all the details you went through making them. Awesome work!

It's been awhile since I last posted. After disassembly to the somewhat bare chassis, I decided to spray the flat bottom with bedliner material for added protection and sound deadening. I used 220 grit sandpaper to rough up the aluminum plate then applied a 2 part epoxy primer as an adhesive...