On my own this evening, dreading more fibreglass cutting!
First thing to finish is the bootbox holes for the RAC rollbar supports and rollbar itself. I set to work cutting, using a dremel cutting disk and sanding drum. Eventually got it to fit nicely. Can't fit it finally yet, as i need to fit the brake light and harness mount points.
I started next on the High level brake light. I drilled a hole in the bottom mount of the rollbar and the chassis that it fits to, i fitted a small tube into this hole. I then drilled three holes for the light itself - two to fix it with self tapping screws and a third for the wire. I then threaded the wire through the tube... this took a bit of fishing... and fixed it all in place. Lots of sealant applied to keep the water out. Finally threaded it all together, fitted the rollbar, and wired it into the left hand brake light. Quick test... it looks great!
I decided to fit the fuel filler cap next... using a rather unconventional method. I drilled a 10mm hole from the inside of the bootbox area, then started gnawing away the fibreglass with a grinding bit. Slowly enlarging, aiming for the perfect location. Finally a dremel sanding disk and its a perfect hole, that lines up perfectly. In goes the tube. Can't finish this as I have no countersunk M5 bolts.
I set to work making a hole for the first of the harness mounts in the bootbox, and got this fitted with a rubber grommet. Three more to do, and its getting a little late for this sort of noise... so i'll finish this tomorrow.
Checking the to-do-list, i finished screwing on the footwell panel on the driver side, and chilled out for 5 minutes painting the tyre with my white tyre pen... you might laugh, but look at my face, bothered?
Next i decided to fit the bonnet catches. Masked the area, rivetted the hook on, pulled it tight, marked the catch, rivetted that too. A bit of sticky foam tape here and there and it fits like a glove.
Todays Build: 1 person, 3 hours.. Total build time so far: 116 hours, 185 man-hours.
