KVA / SGT build

Udo

Member
GT40s Supporter
#81
Yesterday back into the workshop, more rear clip grinding on the agenda. Fig 2 does‘t show the moon surface, but the result of my laminating work. There are still some loops to go . During filler curing, I had time for further installation work. The oil pressure hose shows diameter 4mm, the engine threat half inch - the adapter in shown in fig 1, the installed hose in fig 3. Since engine start is still on the agenda for 2018, fuel tank installation is mandatory. Lying under the car, the breather and reflux lines are visible in the top of fig 4 - bundle of snakes also under the rocker panel

More to follow,

Udo

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#82
Great work Udo and thanks for the explanation. Looked like you had fired a shotgun at the background. ;-)

I reckon my first engine start will slip to 2019 but i’m Starting on the wiring loom installation and busying the dashboard. keep the pics coming thick and fast. I’m following your build in detail.

Best.

Nick.
 

Udo

Member
GT40s Supporter
#83
Looking to the current situation, it would be possible to disassemble the spyder only if also fuel tanks are off the car - no real good solution. Adaptor plates, fig 1 and 2, should make life easier in case of (fig 3 shows the wooden spider rack, for paint and transport). With the adaptor plates, final fuel tank assembly started on left side. Fig 4 shows piping under the sill, and fig 5 the also installed breather hose between tank and filler cap. Copy and paste in half of the time next week on the right side (ctrl c / ctrl v).

More to follow,

Udo
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#84
Hi Udo, faced the same issue on our Forte chassis and came up with a similar solution which might offer a little more flexibility. If your certain your Spyder will not require any minor movements around those bolting down point, no issues. Drop me a PM if needed. Regards. Nick.
 

Udo

Member
GT40s Supporter
#85
Thanks Nick, this will work.

Installed the right tank, it was done in half of the time the left one required. Also filled fuel into the tanks, engine start is getting closer. Besides installation, some work on the panels needed to be done. The pre-owner of the KVA‘s decided to join inner and outer spider panel with pop rivets (hard to believe but true), and one of the holes in the door aperture worked as crack starter, fig 1. I grinded the filler off and laminated some layers onto is - this area will not fail anymore.

Also finish of the rear clip is almost complete. The moon surface is flattened, at least for my level of skills. The painter will for sure have a different understanding ...

More to follow,

Udo
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#86
Pop rivets for that job, definitely hard to believe what some people will do. The work is looking good bud.

Jayson and I whose builds are pretty similar by way of timelines should be shooting for IVA’s mid 2019 if all goes well (one obvious distraction being we purchased another abandoned GT40 project a couple of weeks back, hopefully that won’t slow us down too much. ;-)

I’m shouting for a January engine start (you will probably here the bang from there !), just hope my engine build skill actually pay off. ;-)
 

Udo

Member
GT40s Supporter
#87
Water was next to be filled into the engine, 8 litre in total. No leakage detected so far also in the water hoses, fig 1. Found a flexed hose for the water drain on the expansion tank, and applied a aeroquipp-type of clamp, fig 2, Looks at least important .

With this work done, nothing prevents from engine start any longer! To make the long story short, engine ran for a short period of time (the good news), but a leackage in one of the screw joint on the fuel catch tank stopped the run (the bad news). I am going to fix it next week with highest priority (a stream is available in my German build log).

Since there is still enough work do to, I dealt with some of the remaining: installation of the fuel tank sensor connection (fig 3) and final attachment of the seats including my home-build crossmembers, fig 4. With one exception, seats fitted well, which was a collision between driver seat and gear shifting gate (fig 5), being solved by some grinding of the gate, quite easy.

Hope to make the engine run stable next week, the sound was very very promising already .

More to follow,

Udo

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Attachments

Markus

SPRF40
Lifetime Supporter
#88
Hi Udo,
I was not able to start the video on your website.:(
You make good progress - looking forward to see your car hitting the street by spring next year ;)
 

Udo

Member
GT40s Supporter
#89
Hi Markus, strange, the video works both on phone and pad on my devices. Nevertheless, we may meet in 2020 (2019 is very optimistic )
 

Udo

Member
GT40s Supporter
#90
Fuel catch tank threat repair done, fig 1, and sealed on this connector. After fuel pump restart, another small leakage detected, which will require the disassembly of the catch tank next week, brrr.

Filling of break & clutch liquid was next, no leakage detected so far, but still a lot air in the hoses - will require some more loops to get it all out, fig 2.

The big thing in the late afternoon: the 40 on its own wheels, after month of sitting on stands, it‘s now a complete new impression: that‘s 40 inches high, real flat . The rear clip wheelhouses will require some enlargement, with some further laminating work to come.

More to follow,

Udo
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Udo

Member
GT40s Supporter
#93
Fuel catch tank needed to be disassmbled from the car in order to repair the hopefully last leaking threat, fig 1. After putting it back to the vehicle, bolt adhesive will get a week to fully seal, fig 2, and hopefully close this job.

My silicon water hose didn‘t work in underpressure conditions - a lot contraction and therefore poor durability and water throughput, fig 3. The good old stainless steel hoses will work much better, fig 4.

After refilling fuel and water, engine restart next week will judge quality of my work .

More to follow,

Udo

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Udo

Member
GT40s Supporter
#94
Engine restart was OK regarding leakage, also new underpressure elbow hose works nicely. Still some issues with electrical, to be solved next week hopefully.

Back to rear clip adjustment. Since vehicle stands on its wheels, it became clear that rear clip wheelhouse is way too small, so extensions to both front and rear direction are required. Fig 1 shows the collision and the extended shape. Cutting was easy, the more heavy part will be to bring the vertical flanges (not sure about this vocabulary) around the wheel house aperture - fig 2 shows the „flanges“ during curing.

I bought some more fibres for the work to follow ...

Udo

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#95
There is a rear roll cage fitted already, unless you mean a front cage, but they’re not really any good in a road car...
I would install a front cage - there are several designs that follow the contours of the roof line. In addition, they would reinforce the fiberglass roof. While it may add some discomfort getting in and out of the car, remember you'll be driving a fiberglass car with no fenders, surrounded by two gas tanks , 40 inches off the ground - if I had to do it all over again, I'd definitely opt for the greater protection.

Remember, You only live once!

John
 
#98
Hi Udo, great work as usual. Did you have to make any modifications to the lower areas of the rear bodywork to accommodate your 01E ? If you did, would you post some pictures.

Thanks.

Nick.
 

Udo

Member
GT40s Supporter
#99
I would install a front cage - there are several designs that follow the contours of the roof line. In addition, they would reinforce the fiberglass roof. While it may add some discomfort getting in and out of the car, remember you'll be driving a fiberglass car with no fenders, surrounded by two gas tanks , 40 inches off the ground - if I had to do it all over again, I'd definitely opt for the greater protection.

Remember, You only live once!

John
Thanks for the hints, John. Driving such a car is always a risk, and as Paul mentioned, a cage without helmet doesn‘t make too much sense. I did 25.000 km in my Cobra so far, and - knock on wood - it worked, so I hope to continue with my luck also in the GT40
 

Udo

Member
GT40s Supporter
Hi Udo, great work as usual. Did you have to make any modifications to the lower areas of the rear bodywork to accommodate your 01E ? If you did, would you post some pictures.

Thanks.

Nick.
Hi Nick, the SGT doesn‘t work that well with the Audi gearbox, that‘s true. The left gearbox cover plate needed to be modified like this:
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And the right rear bar of the SGT frame needed to be cut off because of fouling with the cable gear shift mechanism, so I replaced it with a custom made one - I had never done this to my first car, the Cobra :
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