Below is a table of our build schedule. Click the link of any session to read about more detail in the blog entry.
The man hours calculation is generous. Although most of the time there were two of us “working,” it tended to be one of us working on the car, the other would be holding the light or passing the tools…!
| # | No. at work | Hours | Total Hours | Tasks |
|---|---|---|---|---|
| 1 | 2 | 6 Hrs | 12 Hrs | Steering Rack Lower wishbone Spring damper Upper wishbone RH headlight Horns |
| 2 | 1 | 1 Hr | 1 Hr | IVA trim on indicator pods RH headlight wiring |
| 3 | 1 | 1 Hr | 1 Hr | Removal of suspension components Removal of steering rack Trial masking Heat shrink on RH headlight |
| 4 | 2 | 6 Hrs 30 | 13 Hrs | Masking up Dinotrol in engine bay LH headlight Heater installation Washer fluid pipe Gearbox prep |
| 5 | 2 | 5 Hrs | 10 Hrs | Removal of masking Tape up wings Installation of steering rack Install LH & RH wishbones Dry fit RH upright & FARB mounts |
| 6 | 2 | 8 Hrs | 16 Hrs | Finish & fit headlight units Fit & torque remaining front suspension components Fit & torque uprights Fit Front Anti Roll Bar Fit washer tube and wiring. |
| 7 | 2 | 5 Hrs | 10 Hrs | Gearbox onto engine Engine hoist testing |
| 8 | 3/2 | 5 Hrs | 13 Hrs | Engine Install |
| 9 | 2 | 5 Hrs | 10 Hrs | Electrics (Starter Motor) Radiator & fan Cooling Heater Throttle Cable Fuel line Airbox |
| 10 | 2 | 6 Hrs 30 | 13 Hrs | Re-route electrics & final fit Earth lead Exhaust Steering column & rack Air inlet trim |
| 11 | 2/3 | 7 Hrs | 17 Hrs | De-Dion dry fit & brake pipes Hubs Calipers Front brake pipes Handbrake Propshaft Differential DeDion install (part) |
| 12 | 2 | 4 Hrs | 8 Hrs | Watts Links x 2 Rear ARB First fit A Frame First fit |
| 13 | 2 | 7 Hrs | 14 Hrs | List of outstanding snagging Disassemble rear suspension Fit brake pipes to De Dion Fill differential Fit De Dion Spring Damper Units Watts Link Rear Anti Roll Bar Headlight multiplugs Drill lambada probe clip holes Drill & rivet breather bottle |
| 14 | 2 | 8 Hrs | 16 Hrs | Fit "lambada" probe Drill holes in breather bottle & fit hoses Remove & clean propshaft bolts and re-fit with Loctite Gearknob Reversing light wiring Rear carpet header Boot carpets Rivet transmission tunnel top |
| 15 | 2 | 6 Hrs 30 | 13 Hrs | Spring Damper Units Drive shafts De Dion Ears Hubs Uprights Callipers A Frame Handbrake (stop) Throttle cable Transmission tunnel carpet Footwell carpet Seat (test) |
| 16 | 1 | 20 Mins | 20 Mins | Handbrake cable attachment |
| 17 | 2 | 6 Hrs 30 | 13 Hrs | Torque up Watts link arms LH transmission tunnel carpet Top up diff oil Fit last heater hose Handbrake P-clips Boot quarter carpets Boot carpet Fuel filler trim Bulkhead carpet Harnesses Roll bar Scuttle trim |
| 18 | 2 | 7 Hrs | 14 Hrs | Knee trim panels Side panel riveting Seats Transmission tunnel top cover Wing protector Rear wing (RH) |
| 19 | 2 | 5 Hrs | 10 Hrs | Adjust handbrake Torque rear hubs LH rear wing Replace boot floor RH cycle wing: Indicator IVA trim Bighead bonding |
| 20 | 2 | 7 Hrs 30 | 15 Hrs | LH cycle wing (wrong) Rear lights Hood sticks Hood Side screens Mirrors Nose cone Wheels |
| 21 | 2 | 7 Hrs 30 | 15 Hrs | LH cycle wing holes Bigheads bonding RH cycle wing wiring Hood poppers Boot cover Engine Oil Coolant |
| 22 | 2 | 7 Hrs 30 | 15 Hrs | LH cycle wing wiring Brake system fill & bleed Clutch fill & bleed Petrol fill Connect Battery START UP Wipers & washer fluid Fit wheels 12v Power Socket |
| 23 | 2 | 6 Hrs | 12 Hrs | Earth tracing (RH wing) Harness holes in boot cover Boot cover popper bases Paint wing bolts in boot black IVA caps Cable tie electrics & speed sensor Decals Interior mirror Fusebox cover Knee trim panel IVA Bonnet badge Torque wheels Remove axle stands |
| 24 | 2 | 2 Hrs | 4 Hrs | Foam pads on bonnet Rear decal Wheel Centres Relocate mirrors for IVA Second coat of paint on bolts in boot |
| 25 | 1 | 4 Hrs | 4 Hrs | IVA Caps Round off wipers Re-earth brake calliper Re-bleed brakes Remove sidescreen hinges (IVA) Underseal cycle wings |
| Total | 269 Hrs | |||