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| Date | Event | |
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01/12/2003 2hrs Brakes |
Reassembled the RH Brake disk mechanism. |
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3/12/2003 Brakes |
Torque tightened and wire locked the rear brake calipers. |
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4/12/2003 3hrs Handbrake |
Fitted the hand brake calipers. Started work
on fitting the heater to the bulkhead. It's a bit of a jig saw puzzle.
Worked out how the heater fitted to the bulkhead and the cover. It was
necessary to trim the mounting brackets on the heater to get it to fit the
cover. Trial fitted the heater to the cover and bulkhead. |
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8/12/2003 4hrs Bulkhead/ Heater |
Drilled the heater box and
discovered that the best solution for fixing the box. to the bulkhead was
with hex headed self tapping screw. Obtained some suitable screws from
"Unimaster" Mounted the heater, and box to the bulkhead |
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10/12/2003 1hr Bulkhead |
Placed the bulkhead on the chassis and secured it in place with metal clamps to work out the position and drilling points. |
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14/12/2003 2hrs Bulkhead |
With the bulkhead in place drilled the front
face of the bulkhead to match the holes in the chassis brackets. Checked the
height (530mm) from the chassis rail of the top rear of he bulkhead and
clamped in place. Noticed a rather large gap 3mm + at the bottom
front of the bulkhead. Inboard on the RHS. Not sure why this is, contacted
Nostalgia Removed the bulkhead again to drill the side mounting holes |
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16/12/2003 2 hours Bulkhead |
Drilled the side mounting holes. Nostalgia
believe the gap will even out once placed on a bed of mastic during final
fitting. Refitted the bulk head, none of the holes I drilled and
fitted last Sunday line up, opened them out with a rat tail file I will
clamp the bulkhead down at the front to see if I can minimise the gap
and then finish the fitting tomorrow. |
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26/12/2003 6hrs Bulkhead |
During the past couple of
weeks I have worked on the bulkhead intermittently. It involved fitting and
removing the bulkhead a couple of times to mark and drill the side
bolt holes. I measured the sides and symmetrically drilled the
holes in the side of the bulkhead , only to find the rear ones were closer
to the edge of the side bracket on the chassis, than I would have
liked. I slotted these holes horizontally to move them further in from
the edge of the bracket. To facilitate marking of the holes in side
mounting bracket, I stuck masking tape on the brackets where I
expected `the holes to line up. To obtain the correct positioning of
the side bolts I fitted the bulkhead clamped it in place to obtain the 530mm
position. The positions were marked using a mounting bolt with a dab
of paint on the end, passed through the holes to leave an imprint on the
masking tape. Removing the bulkhead again showed exactly where the
hole needed to be drilled. The rear ones were drilled first and they
were slotted vertically to provide adjustment fro the bulkhead. To get the
full range of adjustment I found it necessary to slot the corresponding
holes in the bulkhead The bulkhead was refitted again and adjusted to get
the correct height by slightly rotating forward. The height was measured
using a 6mm flat bar placed across the chassis and measuring the height
exactly with a steel rule (make an allowance for the thickness of the bar eg.
530 - 6 = 524 mm). Once in place an at the correct height the
remaining side bolt holes were marked as before. removed the bulkhead
again and drilled the remaining holes. I found it prudent and
necessary to open all the holes out slightly with a rat tail file. Trial
fitted the bulkhead for the last time and checked that with all the bolts
tightened up the correct height could be achieved. Removed the
bulkhead and placed a bed of translucent silicon sealer in the places
`indicated by the build manual. Refitted the bulkhead. Throughout the
fitting of the we have had a discrepancy in the position of bulkhead as
measured at the datum points. was LHS low and could be adjusted
correctly using the 6mm bar and ruler to position the ruler exactly at
the datum point. The top rear edge of the bulkhead is radiused to ensure
accuracy we laid another steel rule across the top of the bulkhead and
measured where the two rulers met as the true height of the bulkhead.
With the LHS correct the RHS was always high and we had to apply some
downward force to get it correct. the final result was 530mm to within
less than 0.5mm each side. Tightened all the bolts and rechecked
the measurements again satisfactorily. Cleaned up the excess sealer
and left to dry. |
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| Total hours this Month = 22 |
Total hours to date = 451 hrs |
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