The Build Pt1
First stage is to build the chipboard jig. Robinhood in there wisdom supplies two 8' x 4' sheets and after a lot of head scratching you then go out and buy a third. The most important dimension is the centre line from which all the other measurements are taken
First bit, diff and rear wishbone support
Chassis sides and floor rivited to diff support
Another view of the tunnel sides & rear diff support
The Build Pt2
The picture below shows the diff in place before the "15" panels are rivetted in place and form a rigid compartment. Be aware that this seals the diff into the chassis and you will only be able to remove the internals and not the casing after this stage.
Panels "15" rivetted in place. I'm using a hand riveter with extensions made from the Sierra's roof bars. Robin Hood Engineering do sugest the use of an air riveter
Another view of the sealed in diff
The Build Pt3
Next stage fixing the front panel
The Build Pt4
Engine fitting time
The old Sierra had an 1800 CVH engine which I shall be using untill an upgrade. This will involve a little extra work compared to Pinto engines as the main difference is the inlet and exhaust are on opposite sides.
As I don't want to make a hole in the side for the exhaust only to fill it in and reposition it on the other side. I'm going to snake the exhaust under the car!
Painted Stock Engine
The Build Pt5
Due to a problem with a Lightweight failing a SVA test on the grounds that the chassis did not seem to be strong enough around the suspension tubes and a worry about seat belt mounting fixing points.
A group of us met at Graham's to discus ways of improving the design, eat bacon rolls and drink tea. Thanks again Graham.
Here is my attempt at reinforcing the drivers floor starting with cutting ovals so I'm able to bolt the panel in
The edges of the holes were rolled over to add strength and remove the sharp edges
Then the sides are bent to make a triangle box section
Next stage fitting into car