Build Session #4 – Better Check with Derek…

Two whole days of working on the car in front of us… We started off with the rustproofing; masking up inside the engine bay so that we could spray Dinotrol 3125 in the grot traps and troughs where the skin meets the chassis tubes.

Cavity wax
Cavity wax

We also sprayed the inside of the transmission tunnel. In order to give the wax some time to set we then turned back to the headlight units as I had managed to get some 10mm heat shrink. We got the fist one completed according to Daniel’s method and started the second. Unfortunately I managed to pull one of the cables out of the sidelight bulb holder when removing it from the headlight unit.

Ooops
Ooops

In my defence it is quite tricky to get any purchase on the holder. We spent a good while trying to figure out how the connector that the wire had been crimped into was fitted as no amount of force, gentle or brute would remove it. Before destroying it completely we thought we’d check with Derek so added this to the whiteboard to include in an email the following day.

Completed headlight
Completed headlight

We then went back to the completed headlight and in search of “the grommet” referred to in the manual; “Ensure to fit a rubber grommet in the hole in the bracket before assembly.” No clarity as to which grommet,

or which hole in the bracket… We found some likely candidates in the IVA bag, but decided to ask Derek by email too.

 

Heater unit
Heater unit

DSCN0690

Next up we decided to fit the heater as this did not involve the engine bay too much. It went in pretty smoothly albeit with yet another manual ambiguity; “…secure with the washer plates, nyloc nuts, washers and two additional screws from the fastener pack, refer to Fig 58.” The washer plates and nuts were already on the unit, but “two additional screws” was decidedly vague. Figure 58 gave no real clues, so I went to the fastener pack that had been referred to earlier in the section (Fastener pack Cooling) nothing in there would fit.

View of the heater from the footwell
View of the heater from the footwell

The screw hole was threaded, so I knew it was a 5mm thread. I then looked in the Chassis fastener pack and found two  black, 16mm x 5mm screws that looked about right. We decided to use them and check with Derek as it wouldn’t be difficult to remove them.

Contortions required to fit the washer tube
Contortions required to fit the washer tube

As we were working under the scuttle the next job was routing the washer tube up to the nozzle and then routing it down into the transmission tunnel.

Gear "box"
Gear “box”

Another job away from the engine bay was engine and gearbox preparation. We got the gearbox and bell housing out, plus the clutch release bearing that had only arrived in the post that week. Ian the delivery driver had told us it was missing and would be with us in a few days, but it only arrived after I had chased it up with Derek.

Clutch release bearing
Clutch release bearing

We fitted the release bearing which necessitated removing the right angled hose from it and re-inserting back trough the bell housing once the bearing was in place. In order to find the best angle to set the nozzle at we want in search for the clutch hydraulic hose and couldn’t find it… We searched everywhere but concluded it just was not there. Another point for the email to Derek.

Ready to go
Ready to go

The manual states that you should use 4 x M12 x 70mm bolts with plain washers to attache the bell housing to the gearbox. However our bell housing already had four bolts (M12 x 45mm) with plain washers in it. To compound the confusion further the gearbox fastener pack lists four spring washers as being for the bellhousing/gearbox attachment. Guess what? Another question for Derek.