4 & 5th May
Displayed the finished article on the Parallel Designs stand. I had intended to show the car at the Lambo Replica club stand but due to circumstances beyond our control we ended up in a place more suited to off-roaders than low to the ground sports cars. Pictures of the finished car and the full story can be found here in the SVA section for want of a better place.
Spent the previous night at my mother-in laws in London before returning to Parallel Designs to load the car and begin the long trip to the Stoneleigh kit car show.
Loaded the car onto a special trailer and took the car down to Parallel Designs to be checked out and have the windscreen installed.
Today was the last day to finish all the little outstanding jobs that needed to be done. I was in the workshop till almost midnight getting the car ready.
Last dashboard job is to fit the AC control panel which I completed today. I now need to clean the interior thoroughly as testing the heater out had pushed a lot of dust around. Picture in the electrical section.
Installed the side trim panels that cover over access panels for the door latch receivers and fixed the centre console courtesy light and seat belt retractor housing. This part is easily removeable to inspect the seat belt reels. Also took a picture of the gear shift gate. Picture in the interior section.
Spent all day on the sewing machine and covered both doors cards in leather. There is hardly any surface inside the car that isnt covered in leather now, its like being being inside a brightly coloured cow. Picture in the doors section.
Spent the day at route66 bodyworx and with the help of the guys there got the car mobile. Drove the car for the first time today as well! Its obvious the suspension and geomtery still need setting up, but the car pulls like a train. Managed to wheelspin in third....
With the help of an expert in CNC machining at work, I made a gear-gate for the gearshift. Unfortunately I managed to mislay the pictures so you will have to wait to see it installed.
Went down to the paintshop and took advantage of their clean spray booth to install the side skirts. Used a whole tube of structural adhesive to fit them, so they arent going anywhere!
Picture in the General section under body.
Printed some stickers out on the vinyl cutter at work and went down to the spray shop to put them on.
Today the car was picked up by my mechanic friend Danny and taken back to the paintshop. I rode along in the cab and was suprised to see how many people stopped and took pictures in camera phones as we drove by with a Lamborghini on the back of a recovery truck! Pictures in the misc section under body.
Spent most of today in the workshop completing a long list of little jobs that needed to be completed. This work is necessary before the car goes back to the paintshop to work through the snag list.
Installed the wing mirror glass, re-fitted the number plate lights, installed the dashboard top part and idiot-lights. Also installed all the dashboard ducting and repaired a faulty solenoid for the front boot release. Pictures in the interior and doors section under body.
Fabricated the 'idiot lights' today.
Completed the centre console light and it is now ready for fitting. Also installed the wing mirrors and reconnected the wing mirror motor electric s up again. Pictures in the doors section under body, and in the interior section.
Fitted the seats today and fabricated the interior light and seat belt retractor housing. Also began trimming the door panels and made a template for the idiot lights that will sit on top of the dashboard. Pictures in the interior section.
Completed trimming the chassis of the car. Also fitted the weather strip on the drivers door. Pictures in the interior section.
Bonded in the rear quarter windows and trimmed the interior roof bars with leather. Also repaired one of the captive nuts on the passenger seat.
Fabricated an interior light housing and bonded plates underneath the sun visors to take interior trim. Also made the two plates which cover the centre console and trimmed them in yellow leather.
Bonded in the brackets which hold the centre swing clips for the sun visors.
Fitted the major section of the dashboard, about halfway through connecting all the various service up now. Also fitted the passenger side seatbelt. Pictures in the interior section.
Fitted the drivers side seat belt and also fitted the centre console. Will test fit the dashboard tommorrow, weather permitting.
Finished rubbing the laquer down and fitted the dashboard into the dashboard. Pictures in the interior section.
Received the dashboard and centre console back from the carbon fibre specialist. The parts have not been flattened back as they were only laquered yesterday. I will do it myself.
Made the electrical connections to the handbrake microswitch, picture in the electrical section. Also fabricated two brackets to hold the sun visors and bonded them in. Pictures in the interior section.
Made a little lever assembly with a microswitch, cable clamp and spring to detect when the handbrake is engaged. Also blacked up the edge of the speaker panels and cubby holes ready for installation.
Glued the passenger side sill trim in today. Managed to fit it without too many wrinkles to remove this time! Also covered the speaker panels with carpet and will bolt these in tommorrow once I have cleaned up and blackened the edges up.
Stitched the leather panel up for the passenger side sill. I will bond it to the sill tommorrow evening. Picture in the interior section.
Completed trimming the passenger side door sill. Will start cutting the remainder of my leather hide for the passenger side tommorrow.. Picture in the interior section.
Finished sticking the underlay foam to all the parts on the body that require leather trimming. A sticky nasty job but its now out the way. Picture in the interior section.
Fitted the panel that trims the bottom and side edges of the rear window. Also started applying foam to the side bottom sill edges prior to covering them with leather. Picture in the interior section.
Today I trimmed the panel I made for the rear window surround. I also dropped my interior parts off to a gentleman who will be overlaying my interior parts in real carbon fibre. Ive given up with the idea of using any of the commercially available self adhesive carbon fibre stuff as the effect is either poor or the stuff does not conform to the profile of the parts. Pictures in the interior section.
Received my interior parts back all trimmed in leather. The trim on the seats has been straightened up quite a bit, still not perfect but a lot better than before. Stripped off all the carbon fibre effect film off of the interior parts so that I can get them overlayed with real carbon fibre. Pictures as always in the interior section.
Made the small panel which frames the bottom and sides of the rear window. I could not trim it as the 'christmas tree' clips I have to attach it to the bulkhead are too short. Picture in the interior section.
Fitted the two leather covered base plates into the rear window apertures. Pictures in the Interior section.
covering the passenger side of the car including the passenger compartment
Almost completed the carpet on the passenger side now, just the rear cubby hole to do.
Started work on trimming the passenger side now.
Began trimming out interior with carpet and leather. This was more difficult than I thought, the drivers side taking me most of the day. Pictures in the interior section.
Rehung the drivers door with the correct spacers, also adjusted the suspension (stiffened it) and set the ride height to a sensible level.
Identified two areas requiring work back at the bodyshop.
Degreased the hing and repainted it as it got marked when I was freeing it up.
Spent the day freeing the drivers side hinge which for some reason had siezed up. After soaking in WD40 and worrying the hinge backwards and forwards, I got it free.
Test fitted the partially finished side skirts to make sure they are a good fit. They will be sent back to Route66 Bodyworx for finishing before being permanently affixed to the car. Pictures in the general section under body.
Refitted the passenger door and also rehung the rear bumper which was off-centre. I still have the drivers side door to do which is sitting too high on the hinge. I discovered that one of the spacers is missing for the drivers side door so when I fit this it should fit correctly. Pictures in the door section, and some of the new side skirts under general.
6th March 2008
Wow, months have elapsed since any work happened on the car. In that time I put another floor on my house and spent a lot of time in the USA and Eastern Europe. Yesterday and today I began the long process of putting the car back together, starting with the front bumper. Picture in the front bumper section.
Car was delivered back from the painters today pictures in the general section under body, and an image of the almost finished engine bay in the engine section under ancillaries.
Wow, cant believe its been almost two months since my last update. The car has been away much longer than anticipated, but as I have had some problems at home with building work I have ongoing. Updates in the general section under body. Also a picture in the interior section.
The car is now in primer and will be blocked down before sitting for a week for the primer to harden. The next stage involves yet another coat of primer before a final blocking and the application of top coats. Pictures in the body section section under general.
Wow, its been over a month since my last update. The car is progressing very well. Pictures in the body section under general, the workshop section and interior section.
The car was collected for paint today. Fortunately I had good weather and the ground was pretty dry so I didnt drag half my garden down to the pick up truck. Pictures in the miscellaneous section.
Another milestone reached today. Every hole that needs to be drilled, every bracket thats bonded in has now been completed. The car is more or less complete, another snapshot gallery is available here.
Panelled under the front of the car, mounted the door cards, speakers and seats.
Bonded in the rear valance, panelled the bottom of the engine bay to stop road dirt coming up and installed the speakers into the door cards and behind the seats.
Completed all the remaining wiring, including splitting the front foglights and wiring the dipped/high beam on the indicator stalk.
Sealed the floorpan in the passenger compartment with brushable seam sealant and inserted some mountings in for the door cards so as to make sure they are tight against the door.
Installed an interior light, split the front and rear foglights onto separate switches and insulated the exhaust around the starter motor and fuel pumps.
Completed the electric mirror wiring and mounted the motors into the wing mirror shells.
Also made a template for drilling the seat mounting holes.
Completed the wiring for the drivers side door today. I discovered however, that I have a problem with my door hinge on this side in that it now does not seem to shut properly. I have to fix this before the car goes for paint for obvious reasons.
Completed the door wiring on the passenger side and am about halfway through the drivers side. Sixteen individual cables are routed through controlling the electric mirrors, windows and door locks. Also made two plates to cover the wing mirror mountings, picture in the door section under body.
With the exception of the doors and high-beam, all the wiring is now complete. Tommorrow I will finish the door wiring and hope to have the wing mirrors connected up as well.
Worked on the wiring today, completing all the little electrical jobs that need doing before I move onto the door wiring.
Took the front boot hinges apart, cleaned them up and painted them. Reworked the retaining latch and boot seal so the lid sits against the seals correctly
Finished another outstanding job today. I moved the exhaust mounting brackets from the gearbox to the chassis spreader bar, and I also made up the rear tail pipes and installed the fancy chrome trims. Pictures explain this so much better in the engine section.
Installed the second air filter and also installed the engine trim panels. They took a suprising amount of work to install. Picture in the engine section.
I now have a target to build to, the car is booked in for paint on the 4th of September! Also bonded two pipe adapters into the dashboard plenum chambers made from gutter fittings. Covered the main centre console section in carbon fibre film, picture in the interior section. Also halfway through installing the air filters, picture in the engine section.
Cleaned up the fibreglass plenum chamber I made and sorted out bracketry and ducting connectors. Pictures in the interior section.
A trip to my local scrap yard yielded me the remainder of the parts I needed to hook my door handles up and a nice interior light and sun visors from a convertible Audi.
Made up a plenum chamber that fits underneath the top part of the dash to direct air for the windscreen demister vents.
Received some parts from lambostuff today, unfortunately they screwed part of the order up so I have the wrong console light and two non-matching electric window switches. Hopefully get it sorted out soon. Fitted the dash demister vents which were also in the order.
Confirmed with the paint shop and I will pay them a visit this coming Monday to make arrangements for the work.
Painted the steering column cowling today after rubbing it down and fitting some additional bracketry.
Removed the lever for the adjustable steering and continued rubbing the steering column cowling down. Picture in the interior section.
About halfway through the steering column shroud. I had to widen the gap in the dashboard to accomodate it and I may have to drop the tilt and slide functionality completely, its no great loss. Picture in the interior section.
Made the basic form of the steering column shroud today from fibreglass using a aluminium and parcel tape former which I made yesterday.
Started work on the
steering column shroud. Its the one part of the car that will not look anything like the original.
Fitted the door card to the passenger side door, finished the mountings for the glove compartment and cut the holes for the loudspeakers.
Had another body shop come round to quote today, The previous bodyshop wanted the car for five to six months, obviously out of the question. These guys have a website at www.route66bodyworx.com and their work looks interesting. Also completed the glove box and started work on its mounting, picture in the interior section.
Started constructing the internal components of the glove compartment. It will needed to be screwed in after the dashboard is fitted as it needs to be nudged out of the way to fit a few components.
Worked on the dashboard some more. Cut the perspex for the warning light bar, and squared off and finished the plenum chambers for the top vents. Pictures in the interior section.
Mounted the mirrors onto the car today after installing the springs. Pictures in the doors section under body. Also did some work on constructing plenum chambers for the dashboard, picture in the interior section.
After being let down by various paintshops, I think I have found someone professional prepared to do the job. Confirmation depends on scheduling which I should find out about early in the coming week.
Finished the top dash eyebrow part. I modified it to cover some gaps up towards the windscreen and also made a template for the Perspex I will use for the warning light bar. Pictures in the interior section.
Bit the bullet after investigating some other parts from scrapyards etc and bought new switches for the electric windows and the rear courtesy light. Also purchased a set of vents for the demister as I could not find any other suitable ones from lambostuff in the USA.
Started experimenting with carbon fibre vinyl film over the centre console panel. I thought it would look pretty poor, but it actually isnt all that bad. There is some mileage in cutting the film in such a way to minimise joins.
Filled the top of the centre console panel to meet the curved dash piece without any gaps., also smoothed out where any of the pop rivets are so they wont show through the leather.
Worked on the lip that holds the top part of the windscreen. This part is now almost complete. Also worked on extending part of the eyebrow piece of the dashboard so that it covers the join to the body. This would have been visible through the windscreen otherwise.
Dismantled the dashboard again so I can begin the process of making the mountings for the eyebrow piece. Also completed all fabrication work on the centre panel part of the dashboard.
About halfway through fabricating the centre console panel which holds the stereo and AC control panel. Picture in the interior section.
Attempted to make a set of AC fascias from the moulds I took. Unfortunately the resin I used has a high shrinkage making the part overall too small. I need to wait for the 3D printer at work to be repaired before I can make any new moulds.
Had a nice long weekend with the family in Jersey, but theres no rest for the wicked so I was back on the car this evening and have begun fixing the plate that holds the stereo and aircon control panel into the dashboard.
Made up the brackets to hold the gauge plate into the dashboard. Picture in the interior section.
Wired up the gauges into my new dash plates. All functions are now working and this part is now ready to be fitted into the main dashboard proper. Pictures in the electrical section.
Using the two dash plates, I made brackets to hold the two parts apart the correct distance. There are eleven brackets total, which should stop anything flopping about and help tie the top of the dash to the bottom. Pictures in the interior section.
Refitted the door hinges and rehung my doors today. The door action is now so smooth hardly any force is required to move the doors, excellent!. Unfortunately my passenger side gas ram has lost pressure and needs replacing.
Went to another builders today, Chris Barbers and helped with some of the wiring on his Fiero based Diablo replica. Also picked up my modified doors hinges which Chris has had kindly modified along with his own.
Made up the dashboard plate to actually hold the dials. Not a visible part so its quite a bit quicker to make.
Happy Independence day to my US readers!
Today I began assembling the last two AC control panels that I have PCB's for.
Worked some more on the bulkhead. Am in two minds about covering the foam up with something. Also cut the two aluminium sections for the dashboard.
Now all the brackets for the dash have been sorted out, its time to remove everything and foam the bulkhead. Picture in the interior section.
Made up the bracketry for the lower part of the dashboard today, its nice and solid now so its shouldnt rattle when I am driving along.
Filled in the passenger side area below the rear quarter glass, also installed the radiator to body bracket on the passenger side which has been outstanding for some time.
Started filling in the side sections below the rear quarter glass. I have no clear pictures of this area so I am making it up as I go along. Another new picture in the interior section.
Completed boxing in behind the drivers seat, this too has an access port for one of the computers. Picture in the interior section.
Boxed in the section behind the passenger seat. It has an access hatch so the engine computers are not made inaccessible, Picture tommorrow.
Finished sealing up the front boot, completed the headlight access panels and sealed the internal sills against the body. Pictures in the front boot section.
Completed the side sealing panels and also got halfway through making the rear light access panels. Pictures in the front boot and lights section under body.
Finshed the removeable cover which goes over the brake resevoir.
About halfway through sealing up the front boot area. Also modified the sealing lip to make the bonnet sit nicer. Pictures in the body section under front boot.
Started making the fibreglass parts from the templates I had made earlier. These fill in the gaps and stop things in the boot getting wet.
No updates today as I pick up a new car.
Started making templates for the fibreglass pieces to close up the front boot area. These will be fibreglassed at a later date once everything is worked out.
Completed the drivers side door hinge upgrade. Removed the doors now so I can send the hinges off to be re-pinned.
Installed the last part of the hinge upgrade to remove sway from the door. Pictures in the door section under body.
I wasnt completely happy with the aluminium channels spacing, so I removed it and moved it closer. It minimises the gap between the rubber strip and the door glass.
Finished installing the aluminium channel to hold the glass weatherstrip on the passenger door. I need to adjust the position of the top runner to get the glass to seal against the weatherstrip evenly and then this part is complete.
Started fitting the rubber channel on the passenger door. This locates the rubber against the glass and if incorrectly fitted will rub against the glass. I got it too close so I need to redo this part again tommorrow.
Modified the passenger side hinge today to strengthen it. The modification removes all flex from the door side of the hinge. Now all I need to do is to weld a small plate onto the chassis to stop the plate from moving up and down. Also about hlafway through rebuilding the passenger door. Pictures in the doors section under body.
Back from the USA now, so first order of business is to clear up the workshop. Cannot believe how far behind schedule I now am.
Carried on working on the drivers side running board. Made a modification to the rocker on the passenger side to get a nicer shape and cut the fake panels into the drivers side door jamb to match the passenger side. Pictures in the Miscellaneous section under body.
Finished the passenger side running board today and almost completed the drivers side. Updates over the next two weeks will be few and far between as I am away to the US on business.
No updates for the next few days as I am off to the Automotive testing exhibition in Stuttgart, Germany.
6th or 7th May
Stoneleigh kit car show. Chance to meet and greet as well as pick up the essential bits and pieces needed to finish a kit car. Pictures in the misc section.
Problems with my internet connection have meant less updates. Still working on the running boards, but Stoneleigh this weekend means no more updates for a while.
Sanded the window sill down and began filling the void between the bottom of the car and the top of the running board. Picture in the general section under body.
Using a window board as a former, began work on the side sills. Covered the windows boards with a thin layer of fibreglass so that I can use conventional body fillers to complete this part. The reason for doing this is that the boards are made from uPVC and are incompatible with normal bodyfiller.
Put in rivnuts and drilled the passenger side sill to accept the side runner.
Received the drivers side door hinge back from Naz today as well as the special springs for the wing mirrors. Re-hung the drivers side door tonight.
Worked some more on the rear glass surround and also began working on the side skirts.
Completed cutting out the sections required to mount the glass and began making this area good. Pictures once again in the general section under body.
Back to work again. Completed the drivers side glass frame, picture in the general section under body.
Also started putting the rear glass in today. There is more work in this area then I had first thought. Picture again in the general section.
About 80% of the way through the drivers side glass frame now. Ran out of glass fibre and body filler but as I am away on business for a few days now its no big hold up.
Got about halfway through the drivers side quarter glass frame today. It was constant interruptions from visitors so I never got a chance to complete this section.
Completed the frame around the passenger side quarter glass today. It looks pretty good. Pictures in the general section under body.
Didnt get to do much work today as last night someone broke into my garden and smashed a few things up. Spent the evening installing security lights and alarms as my workshop is a fair distance from my house and potentially vulnerable.
Started work on the passenger side quarter frame. The aperture is quite distorted and I have a simple choice here. I can either make it fit right, or fit well. I cannot do both.
I have chosen to make my quarter glass fit well and this means quite a lot of modification to the glass frame to bring it forward.
Phew! Finished the mirror shells today and gave them a lick of paint to check for imperfections. They look pretty good and well worth the time spent on them. Pictures in the doors section.
Wing mirrors almost complete. I need to finish rubbing them down with some fine paper and they are done. Pictures to follow soon.
Back from holiday, still working on the wing mirrors at present. The glass now fits the housings, but as with everything with this car, the pieces are different sizes.
No progress for the next week as I am on holiday. I took some pictures today and put a mini gallery together.
Began working on the actual glass holders for the wing mirrors. The NAERC wing mirrors are different shapes from left to right so with the aid of the some actual wing mirror glass I am correcting these problems.
Ordered a set of Pioneer component speakers with separate tweeters. I will let you know the model numbers if they fit!
Worked on the drivers side mirror mount after casting the area the mirror mounts to yesterday. I did this in the same way on the passenger side as the NAERC mirrors have flat mounting plates whereas they ought to be curved.
Cast the mirror mounting plate on the drivers side as I have the door off and its a job that needs doing. Filled some holes on the door card.
Drilled and put threaded inserts into the doors so the door cards can be installed. Also stripped the drivers side door card of its original foam to repair some holes and other damage. Picture in the door section.
Uploaded a pdf document detailing the modification of Mk3 Mondeo electric window motors for use in a Lamborghini Diablo replica. Details in the resource section.
Carried on working on my drivers side door glass. I am adjusting the front guide by the side mirror mount to allow the glass to slide more evenly up and down.
Also took some pictures of the newly covered seats, take a look in the interior section.
Received my seats back from the trimmers, looking very nice. Pictures soon.
Also worked on the drivers side door glass and sent the faulty door hinge off to Naz.
Completed the drivers side glass assembly. Also had to remove the drivers side door hinge as over the weeks it has become progressively stiffer, to the point where it has seized entirely. This is the second time I have had to replace a door hinge.
As I now have the idlers for the side glass motor assembly, I started work on finishing this door.
Received my rear emblems and engine cover badge today from NAERC. Unfortunately there was an error with the order and I now have one too many bonnet badges and no side emblems. Naz also range to tell me that my side glass is finally here!. The guys from extreme also dropped by to pick up the moulds I made for my Diablo 6.0 dash.
Tinkered with the boot lid to get it to fit nicely. Also received the front wheel spacers and elongated wheel studs for the front hubs. I fitted the passenger side which took a lot less time than I thought it would. Picture in the wheels section under body.
Mounted the bonnet onto the car using my new hinges and a special bracket I fabricated which runs from the chassis up to the bottom edge of the windscreen. Pictures in the front boot section under body
Completed fabricating the new hinges, also received the cut off tool at work I have been waiting for. Using this I made the last parts I needed to replicate my window mechanism onto the drivers side. Pictures in the front boot section under body.
Received the metal I needed for the fron boot hinges a few days ago, so I started fabricating them tonight.
Finished assembling the dials along with the templates. I will make the final versions from aluminium sheet which will be painted black before the fake carbon fibre is applied. Also finalised the position of the rockers at the rear wheels. Picture in the interior section.
Completed marking out the dashboard template and dry fitted the rings.
Started marking out my dashboard template for use with the new rings. I had to move things about a little bit to get them to fit in the way I wanted, Still it looks pretty good.
Finished the wiring to the wiper motor from the steering column. Also started work on the runners which sit along the bottom of the car underneath the doors.
Discovered I need spacer rings for the front wheel hubs as well as longer wheel studs. Im looking at the back now and think I might need something like this there as well.
Received the dial rings today from the engineering works. They look pretty good, even in the raw aluminium. I will probably linish my set and give them a coat of laquer to stop them corroding. Pictures in the interior section, along with some in the electrical section of my lights working.
Wired in the horn and indicators today. Need to pick up more tie-wraps and connectors.
Completed wiring of the headlights, and front fog lights. The wiring to the bumper is through two connectors enabling the easy disconnection when the bumper is removed.
Powered up all of the rear lights, number plate lights. Began wiring the new centre console switches so they activate the correct relays.
Only got two hours in tonight. Managed to remove the front bumper and begin installing the breakout connectors so the bumper can be completely removed from the car.
Terminated the connections on the rear lights and installed the actual light housings. I also completed the cabling to the number plate lights and the reverse switch on the gearbox.
Finished the wiring for the rear lights and rewired the connectors for the front lights.
Refitted the centre console and did some more work on the front boot section as well as added the last part of the centre console. Picture in the interior section.
Worked out a viable hinge alternative to the PD supplied 'solution'. The new hinge will not interfere with the windscreen motor or the wiper blade itself.
Fitted the hinge today to the dashboard and it works well. Its the same sort if design as the front boot hinge. I did toy with the idea of using kitchen cabinet hinges which would have worked but were simply too large.
With the bodywork rapidly approaching completion. Its time to turn my attention to the interior once more. I made a hinge for the glovebox to replace what would have been the passenger airbag.
Installed the wheels on the car today. They really make a difference to it and make it look much more finished now. Pictures in the wheels section.
Started cutting the holes in the console for the electric mirror and window switches. Also started making the various bits of braketry up to hold the dashboard in place.
Played some more with hinges for the front boot and tried a few different ideas out. Got a better idea of what to do now. Also sanded the console sections down so they fitted together again correctly.
Bonded in a lip section so I have something to bolt the centre console to.
Cut the top section from my centre console and drilled holes for the buttons as well as test fitted them. Picture in the electrical section.
Applied a coat of dolphin glaze over the console before rubbing it down again. Picture in the interior section. Also cleaned the workshop out of all the unnecessary junk which has been accumulating over the last two years.
Took the evening off to go and see some friends.
Rubbed the filler on the centre console down
and checked to see how well it fits. Picture in the interior section.
Applied the first layer of body filler to the centre console. The surfaces must be totally flat for the surface to look the way I want.
About halfway through fabrication of the centre console. It looks much better than previous efforts. Picture in the interior section. I also posted a picture of the sewing machine I picked up.
No work on the car today as I had to travel to London to pick up a new industrial sewing machine. I had purchased a machine previously but it turned out to be unsuitable so I got a walking foot machine designed specifically for leather. I got it for a bargain price too! Pictures to follow soon.
Did a little more work on the passenger side wing mirror, I need to make some locating pegs now on my lathe before I can continue. I started replicating the electric mirror mechanism for the drivers side, but managed to snap a tap off in a bearing I was making. No more work on this assembly this weekend.
Got some new hinges from ebay today. These are boot hinges from the escort cabriolet. I really did not like the way the hinges PD supplied work, they were too floppy and the lack of steel in the boot lid caused the gas rams to distort it. On top of this, as the lid is opened it fouls the wiper. The new hinge works in a different way and should eliminate these problems.
Started figuring the wiring out for the mirror motors. I am using Ford Granada wing mirror motors with a Vauxhall Corsa mirror control switch. This switch is the same part as lamborghini used, but somewhat cheaper from Vauxhall.
Received the centre engine cover plate from PD today. Its reasonably good but needs a little bit of work to the lettering which has some distortion, but nothing major that the dremel could not fix! You may have also noticed that some adverts have started appearing on the top of the pages, I hope they are unobtrusive. The aim is to generate a little extra income to pay for some of the elements of my build.
Carried on working on the centre console section. The whole thing is proving more difficult than I anticipated. Pictures soon.
Bonded some aluminium into the rear centre console to take the button panel which also got some reshaping with the fein sander. Hoping to have something that looks vaguely like a centre console by the weekend. Also added some fibreglass to the passenger side door mirror to bring it out to the right length after reshaping the mountings for correct angle.
Could not spend much time on the car today as I had to go round my Grandmothers and fix her TV as she had broken the on/off button. I was able to get some time in the workshop this evening and worked on the wing mirror a little more. Picture in the door section under body.
Finally started the wing mirrors today, and tinkered with the door some more.
Also did some sculpting on the centre console.
Remounted the door and what a difference. The only appreciable play is in the hinge mount plate itself. Picture of the door mounted in the doors section under body.
Ive included details of my plan to remove even this sway there.
Glassed a metal brace in from the hinge all the way down to the
front of the door. Hopefully will eliminate any remaining sway in the door. I will fix a steel bar running from the front of the door to the rear to stop the door distorting from the pressure of the gas ram.
Made some brackets and bolted the runner frame into the door. The glass glides nicely up and down inside the door with no sign of jamming or twisting. Perfect! I will replicate the mechanism onto the drivers side to make it match and replace my earlier efforts. Total cost of electric windows is £130 and some welding gas. Forty quid of that was for the motors I tried first.
Shortened the leading door runner to make it fit as it wasnt quite as nice a fit as I liked it. Wired some fly leads to the motor as it uses a funky ford connector I dont have in my part catalog's. Got the basis of the centre console finished, now will start mating it to the rest of the console.
Constructed a frame to hold the runners and shortened them. Made up the stainless cable which runs the guides up and down. Looks like the leading runner is 10mm too long, which makes the front and back runners different lengths. Started fabricating the centre console parts so I can mount my switches. Installed the front glass guide into the door.
Began work on the passenger side electric window. I am using a different mechanism to the one I used on the drivers side. It uses two rails rather than one and should make for better operation. Picture in the door section.
Received eight switches which arrived today, including a hazard warning switch based on the type I received
yesterday. With the help of a colleague at work I made some white and clear vinyl inserts. I used a white background instead of the original black to match my white dials. Picture in the electrical section.
switch for the console. The lens is a pig to get off but I mocked one up to see what it looks like. Picture in the electrical section.
Just about ready to dump my old sewing machine in the bottom of a lake. I welded and ground the needle plate to repair it, but the damned thing still refuses work correctly. Every hundred or so stiches, it decides to whack the needle into the plate. I am rapidly running out of needles.
Purchased a walking foot sewing machine today as my old industrial machine is too difficult to get parts for. Basically the needle plate has cracked due to it being whacked by needles one time too many. I tried repairing it and getting a new one is proving difficult. Cut out the first parts for the first seat I will be re-covering.
Spent most of the day struggling with my industrial sewing machine. I think it might be time to buy a new one. I made another steering gaiter as I could not get the first one over the handbrake without stretching it when I tried it out for size.
I got the detail stiching much better this time.
Started fabricating interior leatherwork today. Using the old interior I purchased as a pattern I made the gear shift gaiter using the bright yellow leather with black stitching. It came out OK but I need to practice getting the stitch length even. Not too bad for a first attempt.
Made a frame work out of stainless steel to surround my engine computers and close up the interior behind the seats. Its not exact, and I might put some speakers in there yet as well.
Also performed an autopsy on my seats and began dismantling them to make patterns.
Still searching for suitable console buttons and think I have come up with a contender. Now all I need to do is to check the sizes before ordering and fabricating the components themselves.
Not many updates for a while now, due to the christmas break. Although I will be working for most of it, just not on my car...
Started panelling out the interior sections of the car. I am using 4mm thick MDF because I can get loads of it for free, and its really easy to cut and form. Its not as waterproof as plywood and also does not take woodscrews well, which eliminates the urge to use woodscrews completely, which as far as I can see is a major kit car faux pas when building a car.
Stuck five litres of antifreeze into the car today which should be a roughly 50% ratio. Looks like just in time as well because its now pretty much below freezing every day.
Refitted the fuel tank, finished up the rear quarter seals and wired in the new ignition switch. Unfortunately my battery is completely flat so I didnt get an opportunity to put some antifreeze in the engine which is becoming more urgent as the cold weather sets in.
Bonded in the rear quarter sections today. I used pop rivets to fix them to the chassis uprights and then bonded the rest using PU sealant to the body. Once this has dried I will touch up inside the car with some fibreglass paste.
Completed sealing the engine bay from the passenger bay. Also added some high density foam and soundproofing to the fibreglass sections which seal off the engine bay from the passenger compartment.
Rejigged the steering column mounts today as with my original mounting I would not have been able to the shroud around the column in a tidy fashion. It works much better now. I also sealed the passenger side of the rear bulkhead completely.
Started sealing all the gaps between the engine and passsenger compartment. I had put this job off for some time as it involves me spending time flat on my back with resin running up my arms. I am at the stage now where I can put it off no longer.
Began fettling the dash to get it to sit right in the car. I have made a couple of minor errors which took about two hours to sort out, and have identified a problem with the steering column that may require attention. Pictures in the interior section.
No work on the car today because I want a day off from picking bits of fibreglass from my fingers.
Dry fitted the new dash today, short day because I have to go and visit some friends. It requires fettling to get it to sit right but overall I am quite happy with it. Pictures in the interior section.
Success! Finally achieved a succesfull 'pull' from my moulds today. I now have a 6.0 2001 style dashboard ready for fitting and trimming. Pictures in the interior section.
Pulled the moulds from my plugs
today. Spent the rest of the day tidying up the moulds and applying multiple layers of wax. Its suprising how time consuming this all is.
Made three out of the four moulds today, a process which uses a suprising amount of resin. I have to get some more tommorrow after going through ten litres. Pictures in the interior section.
Fiddled with the wiper motor some more and received the gelcoat and release wax for making moulds of my dashboard. Pictures in the interior section.
Fitted the wiper motor today, had to rework the passenger side door hinge to get the wiper to work correctly. Pictures in the electrical section.
Also refitted the new steering column shaft which came back from machining today. Pictures in the chassis section.
Completed the 6.0 style dashboard and now just have to wait for some gelcoat to turn up before I can pull some moulds.
Completed application of filler to the eyebrow, just rubbing down today.
Trip to PD today to pick up the passenger side glass, so now I can finish my doors. Also picked up my tyres which Naz mounted to my rims for me. The only parts I am now outstanding are the passenger side rear quarter glass, seat belts and the rear Lamborghini badge.
Started laying filler over the fibreglass and dowels.
Constructed a frame of dowels and fibreglass to flesh out the flat section of the monobrow. Pictures in the interior section.
Covered the entire top part of the dash with parcel tape and started fibreglassing the front edge into a suitable position. Also started figuring out how the passenger airbag recess is likely to work.
Started marking out the primary dashboard plug as to where the 'monobrow' will fit.
Spoke to Naz today and I will be taking a trip down to Mitcham on Saturday to pick up the remainder of the parts I need and to return some parts I have not used.
Completed rubbing down the primary dashboard plug today. There is a small amount of refining left to do but the shape is pretty much there and looks good. Next stage is to fabricate the top piece before cutting out the passenger airbag recess. Pictures in the interior section.
Picked up a nice steering wheel today from a Tuning shop in Colchester.
It looks quite a bit like the real thing with the exclusion of two small metal bands at the bottom of the wheel. It couples to the steering wheel using a Momo hub adapter and has a functioning horn push. As with nearly all after market steering wheels it needs a cover over the metal centre part to make it SVA compliant.
The entire dash is now covered with filler, and I have begun rubbing it down. It didnt look as uneven until I started smoothing everything out. Pictures in the interior section.
Carried on fibreglassing the dashboard and filling the fibreglassing I completed yesterday with filler. My Neighbour broke my heater, so I have to wait until the fibreglass goes off tommorrow to finish filling.
Back from Germany, so continuing with the dashboard work. I completed
foaming the dashboard and began laying the first layers of fibreglass
down before refining the final shape. Pictures in the interior section.
Began applying the construction foam to my dashboard former. I
have now run out of foam and wont be able to get any more till
next weekend, as I am away on business in Germany. Pictures in
the interior section.
Column is fitted completely, although it is extremely difficult
to reach some area of the metal for welding. It is very secure
now. Also started mocking up the 6.0 style dashboard as I have
decided not to modify the dashboard Naz has supplied. Pictures
in the interior section.
Tack welded the column into position now and checked the position
with the seat in place. Managed to source a key and lock barrel
for the new column which should be delivered next week. Not too
bad a deal at twenty quid.
About halfway fabricating the new mounting posts for the Fiat steering
column. Starting to look like how I imagined it should do. Pictures
in the chassis section.
Began working on the column in earnest now. I have removed the
original steering column mounts and separated the UJ's from the
original linkage to reuse with the new Fiat Coupe steering column.
Got the replacement steering column to update my interior to the
latest style. I now have to remove the original column and fabricate
some brackets to mount the new column in its correct position.
Pictures in the interior section.
Started work in earnest on the interior. There are still some body
jobs left to do, but I need daylight for those, so I will contend
myself with working on the interior as the nights draw in. Pictures
in the interior section.
Managed to source the correct steering column that the 6.0 dash
requires. Have also been busy measuring and checking dimensions
for the dashboard. Got the trim off of the centre console and
the dashboard now in its entirety. Almost ready to start applying
and shaping the foam to build the new dash up.
The last few days have been spent scraping foam and alacantra from
the interior I received. Some of you may be able to guess where
it originally came from, I will not say to spare his blushes.
It has been trimmed really quite badly, I was hoping to use the
trim as patterns but that looks like its out the window now.
Spent the last few weeks travelling on business, so a bit jet lagged.
Returned to my office to find three very large boxes occupying
most of the available space. Due to delays at PD I have decided
to purchase a second hand interior. Some of you may be able to
guess where it came from, needless to say it requires quite a
lot of work. Pictures to follow soon.
Im off to the czech republic next week, so I need to spend some
quality time with the missus today.
Finished fabricating grilles for the rear of the car as the ones
Naz supplies, although very nicely made, simply do not fit. Also
a lot of trouble getting through to him on the phone recently. Pictures
in the grilles section under body.
Got some sort of sinus thing, so thought it best not to spend the
evening in the garage.
Managed to source some of the interior parts today. Not working
on the car today.
Started working on the rear grilles that cover the radiator apertures.
I had ordered a set from Naz, but they seem to be a different
size and shape from mine, So I am fabricating my own.
All lambo'd out, so I am taking the day off.
Installed the lower door glass weather seal onto the drivers side
door. Yuck, what a horrible job. Pictures in the doors section.
Finished rubbing down the inside wing area of the drivers side
door, and adjusted the lines to the rear of the engine cover. Pictures
in the general section. I
also completed the front boot latch area, pictures in the front
Completed the drivers side door secondary seal today,
and resumed work on the front boot lid latch area.
Fitted the secondary weather seal to the passenger side door today.
About half way through on the drivers side. A difficult and time
consuming job not made easier by the lack of a suitable recess
on the body for this part. Pictures in the general section.
Fitted the completed front bumper, and began work on the secondary
weather seals. This is a time cosuming and fiddly job, which
if rushed or bodged will be extremely visible. Pictures in the front bumper and general section.
Fabricated and installed the ducts for the front bumper. These
hold the foglights and are closer to the original than the solution
I saw fitted to PD's green demonstrator. Pictures in the front
Fiited the bracketry for the side lights and began prepping the
bumper for paint. Pictues in the front
Fabricated the brackets to hold the drivers side headlight in.
No work on the car today as I had to go round my parents house to fix their computer.
About halfway through doing the false wing effect on the passenger
side. Naz does a template which is supposed to give the impression
that the one piece body is in fact made up of lots of different
panels, I just didnt think it was that realsitic. See my efforts
in the general section under body. Also dry fitted the drivers
Got the wiper blade and the secondary door sealing strips today. Also started
marking the passenger door out to give the false wing imprint.
Placed three mounting positions on the front boot lip to tie the
bumper in correctly here, pictures in the front
Got the missus rubbing the gelcoat down to give a good key. Also
updated the doors and front
bumper sections with more high resolution
At my Nephews Christening today, so no work on the car. I have
updated the site however, Full size images in the engine section
available, more sections will be added as I process them.
Spent the day correcting a bulge in the roof line and bringing
the low points at the leading edge of the roof into line. This
takes a suprisingly long time to complete, and quite a large amount
of glass fibre and body filler. Pictures in the body section.
Made some small brackets that will hold the rear engine cover down.
I had originally used bolts but these would be inaccessible with
the rear grille fitted, so I had to rethink its mounting. Also
started work on the revision 2 of the AC control panel as the prototype
has been returned after extensive testing. There are a small number
of insignificant bugs still to iron out, but overall the prototype
has functioned well.
Another milestone reached! I have open and close doors, with locks,
push buttons and more importantly, Gas Rams! Pictures in the doors section as always.
With the aid of my borrowed MIG welder I have attached the bottom
Gas Ram mounts to the chassis.
Filled the voids in the rear passenger compartment voids. No pictures
until I have cleaned this up because I am universally bad at
applying expanding foam. Also started work on the chassis gas
ram mounts. Unfortunately I was not able to borrow my neighbours
MIG welder to finish this job.
Due to still having sore fingers on my left hand, I tidied up my
workshop today and pop rivetted the glass fibre panel to the
rear of the passenger compartment, ready for foam filling.
Managed to crush the fingers on my left hand today when I dropped
the now very heavy drivers side door onto them. I now have too
black finger nails and some very sore fingers.
I am also removing the link to DCSupercars with regards to the
gearbox adapter until the current argument concerning ownership
of the design is settled.
Completed roughing out the door edge and gave it a lick of paint
to see how far out any sections of it are. Also cut in the Engine
cover release into the door sill. Pictures in the doors section.
Working on the drivers side door gaps at present.
Tweaked the door button rod for a more satisfactory lock and unlock.
I also started work on the body where it meets the door to even
up the gap in this area. Pictures
in the doors section.
Took some time off work today and went to Galaxy Models in Ipswich
to get some ball and cups for the locking mechanism. Assembled
a lever arrangement on the push button and now have a functioning
key lock on the drivers side door. Given the effort that required
to complete this, I may not bother doing the passenger side
Mounted the lever from the door pushbutton to the locking mechanism
and started work on the key lock mechanism. It looks like I need
some more ball and socket joints.
Modified the motor mounting to prevent the door from flexing when
the glass hits the top or bottom of its travel. Also fitted the
push button and servo for the locking mechanism,
Got the glass sliding up and down via the modified motor on the
drivers side. It took a little rework to get everthing operating
properly, but it all works correctly. Pictures in the doors section.
Shortened the drivers side electric window motor ready for fitting
it tommorrow. Took a little longer than I expected, but I am
ready to fit it and the glass to the drivers side door tommorrow.
Pictures in the doors section.
Mounted the vertical part of the door frame for the glass, and
bonded in a section of aluminium behind the wing mirror mount
to hold the glass rubber in place. Almost ready to start fitting
the electric window motor.
Carried on working on the door today in preperation for fitting
the glass. Also started on the work on the gas ram chassis mounts.
Completed the door seal area today and raised the sill edge to match
the passenger side. Still some more work to do in this area. Also
fitted the top part of the aluminium frame to secure the glass rubber.
The door is much stiffer as a result. Pictures in the doors section.
Cut the old door sill off, taped my foam to the door, and glassed
in a new sill to suit. Some tweaking will be needed to get the door
seal entirely even, but this is easier than trying to fix what is
Fitted the door handle to the drivers side door. Its much easier
to lift the door with this on, something I will need to do much
more of in the next few days.
Finalised the position of the door latch receiver, and fitted the
door handle to the drivers side door. Also test fitted the glass
and discovered that the pre-bent aluminium channel that Naz supplies
needs tweaking to match the glass profile. I am very glad I have
not fitted these yet.
Fiddled some more with the door latch receiver to get the right
Got the door clearing the wing with the same amount of space as
the passenger side. I ended up with a 2.5mm spacer on the drivers
side between the chassis and a 10mm spacer on the passenger side,
unsure as to why this should be, but I am not going to spend a great
deal of time worrying about it. The gap at the bottom of the drivers
door is fairly huge and will require a fair amount of filling, but
I will do the door seal first to get this correct.
Started finalising the door position. Managed to get the door to
clear without rubbing the wing and have fitted the door latch and
receiver to the body. Pictures in the doors section.
Still playing with the hinge spacing at present. Made some more
adjustments and carried on making good the cuts I made to reposition
Corrected the position of the wing this evening to minimise the
gap against the door. The next few days will be spent evening out
the gap and making this area good. Pictures in the doors section as always.
Started hanging the drivers side door. Bugger, the drivers side
wing is almost ten millimetres out and needs to be shunted over.
I am glad I got the windscreens from Naz now, as it has highlighted
another slight problem with the bottom edge of the windscreen. Pictures
in the doors section.
Reworked the latch receiver on the boot lid to work better with
the new mounting position on the bumper mounting lip. Took much
longer than I though it would.
It is said that its a womens perogative to change their minds. Well I
have gone a bit feminine and decided to change an area which I had
previously worked on before. I had made the mounting lip for the
front bumper out of fibreglass. This is the area covered by the
front boot lid. As it is visible even with the boot lid down, I
have decided to look at it again. Pictures in the front
cover section under body
Finished fettling the passenger door today. Sort of half way through
the doors now, which is good. Pictures is the doors section
Went to see Naz today. Picked up two windscreens and the drivers
side glass. The passenger side glass wasnt there so I will have
to make another trip to fetch that. No problem as I can pick up
some interior bits then as well.
Got through to Naz, after a few days of trying. Am going to PD on
friday to pick up the glass.
Fitted the rubber seal to the new lip and refitted the door. I now
have a good seal all the way around the door. Its being pushed out
slightly at the top of the door and at the bottom edge, but these
are minor things I can correct quite easily with just a little sanding.
Filled the seal to give a nice finish and applied a coat of primer
to see where I am. There is a touch more work to do on the lip,
but its very minor. Pictures in the doors section.
Finished building the seal up and began grinding the new lip to
achieve a flat surface, a LOT of dust.
Mother-In-Law came round, nothing happening today...
Carried on working on the door seal. It looks pretty good now. Pictures
in the doors section.
Almost finished glassing in the new seal. The tape worked pretty
well with only two areas that need a little attention. I used three
layers of fibreglass tape, and then gave it a skim of bridging compound
to even out any irregularities. I will stick another few layers
on the inside thursday for extra strength.
Bake from Cleveland, started work on the passenger door rubber seal
lip. I began by cutting the old one off flush with the door. Then
I taped the door with parcel tape, and placed 10mm foam on top of
the tape. Another layer of tape finished this off and gives me a
consistent gap all the way around. Using fibreglass tape I then
glassed a new lip on all the way round. It took me about two hours
to complete this process.
No progress up to now, and for several days yet. Several problems
have ganged up and attacked me all at once, which means I have been
able to do zero work on the car. First problem, the floor in my
bathroom needed to come up and be replaced so the foundations could
be inspected for my upcoming loft conversion. This took much longer
than anticipated. Then Royal Mail decided to deliver the special
tapes I ordered for the door seals to someone else, I have only
just received the replacements. Then I need to go to cleveland in
the USA next week on business. On top of all this I was supposed
to get the glass pack from Naz last weekend by the van I intended
to borrow was not available. Better luck soon I hope...
Installed the push button for the door latch on the passenger side.
Pictures for this and the last few days work in the doors section under body.
Began working on the door gap around the latch area of the door.
Foamed the front portion of the drivers side door aperture to stabilise
this area. I also fibreglassed the wing to the chassis.
Still working on the passenger door area. The top and bottom of
the door towards the rear of the car match the profile of the rear
quarter panel. However the bit in between is grossly distorted.
I spent a good few hours with the sander roughing the shape to something
halfway sensible. Unfortunately I have had to remove so much fibre
glass from this area, it is now unacceptably thin. I need to build
up the panel inside the car now to rectify this. I am still waiting
on the parts for the door seal, so no progress there yet.
Had an idea on how to rapidly fabricate a new door seal edge. I
have ordered some bits and pieces to complete this task, I will
let you know how it turns out.
Also did a little more work on the door latch, I also foamed the
front part of the sill to the chassis to provide some stability
in this area as I work on it.
Completed the door edge gap against the wing, finished the latch
receiver and carried on working on the front boot seal. Pictures
in the doors section and under wings.
Fitted the spacer plate to the hinge today. Its stopped the hinge
flexing against the chassis completely. Any sway is now exclusively
in the door and the hinge to door interface. Once the glass is installed
this should stop the door itself flexing, and I wil glass a steel
insert into the bottom of the door extending up to the hinge to
reduce sway further.
Manufactured the spacer plate and an additional plate to sandwich
the hinge between two substantial pieces of metal.
Fitted the new gear shift mechanism and it works superbly. I can
now select reverse with relative ease. It should be a lot easier
to change gear now, although I need to get the car moving again
to confirm this.
Also been working on the passenger side door hinge. I have been
trying to fiddle with it to lose the washers spacing everything
out. I think I have figured out what I need, there are now no washers
on the door to the hinge, and a spacer plate of 8mm is needed from
the chassis to the hinge itself, which I will probably make at work
Stayed late at work and completed a new gear shift assembly to replace
the current one I have. The existing setup works fine for selecting
3rd and 4th gear, but all the other gears are a pig to get into
to, especially reverse. Careful examination reveals its because
the side to side movement of the gear stick causes an unwanted rotational
movement on the selector shaft as is it slides in and out. My new
selector is slightly more complicated, fixes this problem and gave
me an opportunity to try some real precision engineering. Pictures
in the gearbox section.
Installed some bumpers onto the rear engine cover latch bar to hold
the engine cover in a fixed position better than the latch alone.
I got the bumpers from an Audi 100. They are usually used to hold
the boot in a fixed position in that vehicle and work pretty well
in this application.
Spoke to Andrew today, another Lambo builder, and discovered a minor
problem with my wing mirrors. One is slightly larger than the other.
This is the case with a number of cars, my Mercedes has a larger
passenger side wing mirror. But this is not supposed to be the case
with the Diablo however. I will need to modify one of the mirrors
to match the mirror glass when I get hold of it.
Fitted the rear grille and front bumper today. I need to do some
more work on the gear selector, it has too much play in the side
to side orientation at present making the gear change uncertain.
Also dry fitted the front indicator side light assembly's. I also
noticed on the drivers door that someone has helpfully cut out the
recess for the push button lock and has done it too large. More
work in this area needed.
Finished the door handle on the passenger side off today. A suprisingly
long time is required to get it fitted right. Pictures in the door section under body.
Started cutting the apertures for the push button lock and the door
handle. Due to restricted space, I will complete one side of the
car before turning it round to work on the other.
Fitted the passenger side door latch today, and the receiver on
the body. It takes a little fiddling about to get the latch to fit
the recess on the door correctly, and careful measuring to get the
receiver in exactly the right position. I had to cut a rather large
section out of the door aperture sill to get the door to fit correctly,
otherwise the door would not drop down in to the recess. Pictures
to follow soon.
Finished forming the bottom edge of the wing, It looks a little
better but still does not quite match the other side completely.
You need to draw the line as to how accurate you intend to make
things, and I think this will pass pretty close inspection.
I have been working on the drivers side wing again as I wasnt happy
with the way the wing flared out at the bottom. The drivers side
looks ok but is too short and needs extending a few millimetres,
and the passenger side kicked out at the bottom rather than in.
I have rectified the problem and just need to run a skim of filler
around this part to finish it off. Pictures soon.
Drove the car around the garden late last night. The clutch is not
as heavy as had at first thought, although I need to bleed the brakes
again as they feel a little spongy. Gear shift needs tweaking as
its difficult to get into reverse as it currently stands. Didnt
need to touch the accelerator, it certainly is keen to go.
Replaced the bad board interconnect with a more robust IDC connector
setup on the AC control panel. Its a bitch to assemble but the connection
is much more reliable and not susceptable to vibration. I will test
it and send it back to Naz so he can run the compressor tests on
his gassed up system.
Well I am back. My time recently has been taken up fixing my roof
and repairing the damage some high winds caused to my property.
I managed to find some time to take a look at the door locks. I
also fitted some new leads which the engine has been needing pretty
badly. I have received a fair number of parts from Naz so I have
a fair amount of work to do.
The AC control panel has arrived back from Naz's requring a little
rework before approval, basically the board interconnect is not
reliable enough and the logic for the compressor drive is inverted
with respect to Naz's wiring loom.
OK, no updates for a little while as I am having a fair number of
problems right now which are taking up a lot of my free time. Basically
the roof on my house is falling in so I need to spend some time
fixing this before I can complete any more work on the car.
No updates to speak of as I have been a bit under the weather. On
top of that my significant other has been away so I now have to clean up the
mess I have made of the house.
Ran the engine for over an hour today after filling up and bleeding
the radiators. It takes a while to get rid of all the air locks,
but perseverance pays off and now the car happily idles at 90 degrees
celcius with the fans cutting in and out to regulate temperature.
The right hand rad fan never actually switched on during testing,
which proves how effective the radiators actually are.
Got the engine running on 12 cylinders again, I had managed to switch
two cables on DME 2, specifically the Anti-Theft and DME enable
lines. This is both my fault and BMW's. Mine for not paying attention,
and BMW for making the cables the same damned colour. Pictures of
the exhaust system in the engine section under ancillaries. Also I have uploaded a short video of my engine
running with my number two at the cars controls, you can download
the video from the miscellaneous section
I now have the exhaust fully fitted now, with exception of the decorative
tips. Unfortunately its a case of two steps forward, one step back.
The engine is now running in limp home mode on only six cylinders.
I need to borrow the Diagnostic computer again to locate the fault.
Pictures of the exhaust to follow soon.
I received the final parts for the exhaust system at the stoneleigh
show, and have been fiddling about getting everything to fit right.
Pictures to follow soon.
Two new videos of Parallel Designs Miura V6 and Diablo V12 uploaded
to the misc section, along with a couple
of pictures from the Stoneleigh kit car show.
Stoneleigh weekend! The worlds largest kit car show. Pictures to
Been away on business in Germany this week so no updates.
Completed the mounting of the high level third brake light. Pictures
in the rear engine cover section under body.
Major update. Completed the first AC Control panel today. Pictures
in the electrical section.
Also began work on mounting the high level brake light onto the
rear mini-wing above the rear window. I have used a combination
of steel, araldite and fibreglass to make the 'box' that will enclose
Carried on working with the rear mini-wing.
For those of you wondering as to how progress with the AC control
panel was going, I have an update. Picture in the electrical section.
Reworked one of the boot lid hinges to prevent rubbing as the cover
is raised and lowered. Also dry fitted the mini wing that sits at
the back of the car above the rear window. Pictures in the rear
cover section under body.
Completed preliminary work on the engine cover. Pictures in the rear engine cover under
the body section. Mounted the front latch and gas ram for the front
boot, pictures in the front
cover section under body.
Started work on headlight mounting, pictures in the headlight
section under body. Also continued work on the rear engine cover.
Began work on dealing with the poor gaps around the rear engine
Completed the glassing in of the front wings.
Still glassing in.
Its always the little jobs that take the longest amount of time.
I fitted the latch for the rear engine cover and the receiver for
it to the chassis rail. The latch is fitted using rivnuts and I
bought a budget tool to fit them. Pictures to follow soon.
Still glassing in the front wings, but have not had much time to
devote to the car as the weather has been good and have been working in the garden instead. Hope to do a little more tommorrow.
Continued glassing in the front wing today, about halfway through.
I am not very good with fibreglass matting.
Performed the fibreglass equivalent of tack welding the front wings
to the boot liner. Once this has cured, I will remove the bumper
and complete the fibreglassing all the way round.
Not much progress today. Had a guy come over to look at the car
with a view to painting it. Did a little work on the front bumper, its now
bolted into place.
Bit of a disaster today. My dog bit the thumb off my right hand,
this means I will have to complete the car using only my feet and
remaining left hand...
On a lighter note, I managed to manhandle the exhaust cover into
position using my feet. Pictures in the rear
cover section under body. I also clamped up the front bumper
in preparation to mount this tommorrow, pictures in the front
bumper section under body. Also picked up the remaining rubber
boot for the bumper mountings.
Picked up one of my rubber 'boots' today, the other should be in
tommorrow. Mounted my newly constructed light surrounds in, pictures
in the rear lights section
under body. I also made up the mounting bar for the rear cover latch,
exhaust mounts and began work on the exhaust cover. Pictures in
the rear covers section
Ordered two bumper rubbers from my local Ford dealership through
Naz. I should be able to pick them up tommorrow. I also spent some
time on the rear light surrounds, constructing the mounting brackets
for the lights themselves and the entire surround. Pictures in the rear lights section under
Had to go and repair my mates digger today, So didnt make much progress
on the car. I did however have to time to make some brackets to
connect the chassis to the rear bumper brackets. Pictures in the rear bumper section under
The culmination of two days solid work is I now have the rear bumper
fitted correctly. This was a far more time consuming job than I
thought, but at least it is done, and doesnt look too bad either.
Pictures in the rear bumper and rear valance sections
Spent some more time on the rear valance. I dry fitted the rear
bumper with this component fitted and it became apparent that the
bowing problem is not just due to the gearbox. The problem is also
due to the chassis protruding too much and forcing this component
out of line. The net result is that the valance touched the rear
bumper when there should be a gap. Pictures tommorrow showing my
resolution to the problem.
My beloved has gone to New York for the week with my mother, so
I am left at home on my own. Cool, should be able to get a fair
amount done on the car this week.
Fitted the rear bumper in preperation to make the brackets up for
the rear bumper. I need to modify the rear valance to suit, by cutting
holes for the brackets and by also modifying the shape so that it
does not touch the rear bumper. Hopefully this will also sort the
problem out where the bottom part of the radiator grille apertures
are out of shape. Pictures in the rear
bumper section under body.
Fitted the front boot lid, and pulled the car out of the workshop
to give it a blow down with the air line as all of the cutting and
grinding of the body had left a nice thick blanket of dust over
the car and my workshop. Dry fitted the rear bumper and it looks
like I am going to need to do some more work to the rear valance
to get everything to fit properly.
Received some major components today! Six months after ordering
them I finally received the exhaust system. I am still missing one
link/down pipe and some bracketry, but I have two large boxes full
of stainless steel tubes and bends. I should be able to assemble
the exhaust next week when the brackets and extra pipes arrive.
I also dropped the front boot lid brackets to my buddy Danny, who
will make the alterations required to make the hinges work. I had
to fix his wheel balancer as payment.
Pictures to follow shortly.
Started work on the front boot lid. Pictures in the front
cover section under body.
Completed the drivers side headlamp. Pictures in the electrical section. Also uploaded a picture of the mould and prototype front
panel for the AC control panel.
Got a migraine today, so no work on the car.
Picked up some chrome effect paint to recover the projector
bulb reflector as all the chrome had pretty much flaked off.
Got some paint from halfords which looks like it matches the colour
inside the drivers side headlamp. Also made a mould of the parts
required for the AC control panel. Pictures soon.
Finally got the masters for the plastic work on the AC control panel.
These are generated using a sterolithography machine I recently
purchased for work. The machine is hugely expensive but makes construction
of prototypes using ABS plastic very easy.
Began work on the drivers side headlamp. I have previously completed
the passenger side but had not got round to reconditioning this
one yet. Externally it is much cleaner then the passenger side,
but inside its much worse. The projector bulb has significant peeling
of the paint around its housing which will need to be rectified.
I have found that white spirit dissolves the glue and sealant much
better than the other solvents I had been using up to this point.
Received my wing mirrors from the USA today. I would have bought
the parallel ones, but the ones I got were cheaper, although they
do require a little more work to get ready. Pictures in the doors section under body.
Completed the external work required on the body for the filler
cap. Also rehung the drivers side door with the new hinge. I also
moved the passenger side door pillar on the body as it was set 5mm
out of line on the body compared to the drivers side. Pictures to
Been away in the Czech Republic at a friends 30th birthday party,
so have not had much time to work on the car. I got back into it
today by begining work on the fuel filler cap. You can see the first
steps in this process in the misc section under body.
More work on the drivers side wing. Looking pretty good now, Pictures
in the wings section under body.
Carried on building up the drivers side wing edge to match the door.
Pictures in the wings section
Updated the body section as it was getting a little full and took
a long time to load up. Also changed links site wide to suit. Try
it out, feedback always appreciated. I also started work on the
passenger side wing, trying to get that in to the correct shape.
Pictures in the wings section.
Major progress. Hung the passenger side door today. Also removed
the passenger side wing and bonded the new style wing in its place.
Pictures in the wings section under
Began to hand the passenger door and completed building up the shape
I want for the inside of the door jamb on the drivers side. Also
removed the passenger side wing and began work on fitting that.
It looks like I may need to adjust a pillar on this side and apply
a little heat to the new passenger side wing to get everything to
line up nicely. Pictures to follow soon.
Completed bonding the new front wing onto the drivers side, and
began to fill the remaining gaps and voids with fibreglass bridging
compound and body filler.
Uploaded a picture of the initial prototype of the AC Climate control
panel I am working on powered up. Picture is in the electrical section.
Also began bonding the new wing into place. I hate fibreglassing
with a passion. Its gloopy horrible stuff that get everywhere. Pics
Major progress today. I found my digital camera so loads of pictures
in the wings section under body.
The drivers side door is fitted and aligned and looks pretty good.
Not nearly as bad as I thought it was going to be. Next step is
to bond the new wing on, and move round to the passenger side.
Mounted the drivers side door and began work on mounting the new
wing. Almost immediately discovered a minor problem with the hinge
that will need rectifying at some point, the moving part is to close
to the fixed part and is rubbing to the extent that its removing
material. I managed to get it moving by worrying it backwards and
forward in a vice, but this is obviously a less than ideal solution
for the long term. Fiddled with the new wing and discovered I may
have removed slightly too much material. I will look into this after
speaking to Naz.
Bit the bullet and cut the drivers side wing off ready to accept
the new wing. Scary stuff. I used an angle grinder to remove the
majority of it. Also reworked the boot lid hinges a little to improve
the fit, bonded down the rear window and shortened the drivers side
gas ram to allow for the different mounting position on this side.
Dry fitted the drivers side door again, things are starting to look
pretty good here. Pictures, as always to follow shortly.
Carried on working on the boot lid today. Its a very fiddly job.
Not helped by the fact the mounting plates on the newly supplied
boot lid for the gas rams are in slightly different places. I will
need to space one of the rams slightly to make them the same length
and hence the lid parallel when its up.
Work is calming down now, so got an opportunity to start assembling
the newly arrived engine cover. Managed to get one of the hinges
fitted, hope to do the other tommorrow.
Not too much happened last week. I have been working on the software
for the AC panels and this is almost finished. Still waiting for
the replacement engine cover and door hinges.
Completed construction of the first of three prototypes for the
climate control panel. I will make the other two when I am sure
I have dealt with all the major problems with this one. Pictures
in the electrical section.
Naz has contacted me to replace the rear engine cover. No indication
as to how long this will take. Fingers crossed it will be done with
Began assembley of the first three prototype climate control panels.
Discovered an alignment issue with one of the inter-board connectors,
but this is what prototypes are for, and it is easily fixed for
the next revision. Pictures to follow soon.
Yet another problem. There is no metal in the engine cover, which
means I cannot mount it. Pictures in the rear
covers section under body.
Bonded the body down to the chassis today. I used a fair amount
of clamps to hold everything in the right place as the epoxy dries.
Pictures in the general section
My mate Danny came round and welded the roll cage in today. This
is a job which has got to be much easier with the body actually
off. Whatever the material the rollbar is made of is nasty to weld
using pure argon as a shielding gas.
Now it is secured in I can see exactly where I need to pull and
push the body about for a correct fit. Unfortunately its too cold
to bond the chassis and body tonight, so I will need to wait until
tommorrow for this next major stage. Pictures to follow.
Received the Printed Circuit Boards for the AC control system. Pictures
in the electrical section. They have
arrived early so I dont have the components yet to actually begin
assembly. Also figured out the cabling for the Fiat Coupe switch
gear with regards to the windscreen wiper.
Rebuilt the windscreen wiper motor following instructions supplied
by Parallel Designs. Pictures in the electrical section.
Back from my trip away, but full of flu, my other mistress has banned
from the workshop until I am feeling better.
Wired up some relays for the lights, as the new style steering column
switches are not able to handle that much current on their own.
Off away on business again tommorrow, so no updates until the 22nd
at the earliest.
Fitted my modified rear valance today and it looks pretty good.
Pictures in the rear valance section under body.
Started work proper on the body today, pictures in the general section under body.
Picked up supplies for starting work on the body.
No updates as I have been working on the AC climate control panel.
The Plastic bezel is being designed now and I am trying to source
cheaper components to bring the price down somewhat.
The roll cage arrived today along with a box of hinges and adhesive
to bond the body to the chassis. Unfortunately, the door hinges
were missing, and a part of the roll cage had gone astray during
shipping. So I wont be bonding the body down this weekend. Still
no exhaust, and no idea of when its going to arrive.
Spoke to Naz today, expressed my dissapointment of the fit of the
drivers side door and worked out a possible method of correcting
the problem. Completed the PCB designs for the AC control panel.
These will be offered for sale through Naz at parallel. I am happy
to answer questions on the control panel, but sales enquiries need
to go to Parallel Designs now.
Happy new year to all. Not many updates over the last week as I
have been working on another aspect of my build. I have been prototyping
a climate control panel to replace the god awful thing that comes
with the Vintage Air A/C system. Pictures in the electrical section. Also dry fitted the drivers side door, pictures in the door section under body.
Installed the cabling to the AC compressor and trinary mode switch.
Tidied up the cabling running down the centre console as it was
starting to get a bit messy. Pictures in the electrical section.
Installed the VDO engine oil pressure sender unit and connected
it to my gauges. Also ran cables to the Air-con compressor and bi-mode
Installed my dummy dashboard and indicator panel into the car today.
Need to wire up the drive signal for the rev counter and to fit
the replacement oil pressure sender, all the dials will be functional
Made a dummy dashboard today to mount the gauges on so I can test
them. After a little initial confusion with the speedo caused by
my bench power supply, I got them all working OK. I can now continue
with the instrument wiring.
Been a little bit manic recently, christmas shopping and work getting
in the way. Have mounted the fuse box in the front boot area, and
drilled and tapped one of the rear manifold caps to put a vacuum
feed for the brake servo. Pictures as always to follow.
Got back from San Diego yesterday. Will talk to Naz about body problems
I have also completed a tutorial for getting the M70 engine's OEM
ECU's to work in a kit car. You can download it here.
Its in Adobe PDF format so you will need a reader to view it.
I am working in San Diego next week, no updates until I get back.
Started to align the body today. What a mare! Nothing seems to line
up and the only points of reference you actually have to begin from
are the wheel to front arch clearance. After much pushing about,
have decided to call it quits for tonight, think about it and have
another crack tomorrow night.
Received the bumper segments from Naz today. Also an oil pressure
sender, not much use yet as I have not got the adapter for it yet.
Drilled and tapped the rear waterway link pipe to accept a new temperature
Fiddled with the body a little more today. Cant actually fix anything
down yet until I get the bumper sections from Naz to fit so I can
align the body properly. There is still a number of other things
to do yet. So I will continue on with those for the minute. Uploaded
pictures of the bodywork onto the general section under body.
Dry fitted the body to the chassis today. It took four of us to
lift it on to the chassis. It had sagged considerably during its
time from Parallel Designs, and took a lot of effort to get it anywhere
near the correct position. There are a few things left to complete
and check before I can bond it in place.
Completed the mechanics of the gear shift assembly. Re tapped a
hole on the rear water pipe linking the two heads to accept a VDO
temperature sender. Also bled the clutch and checked its operation.
Installed my new gear knob. Its not at the proper height yet, and
I still have a shift gate to make, but it all looks pretty good.
Pictures in the gearbox section. I will
be away on business in Germany over the next few days, so no more
updates till the weekend.
Removed the boot liner, ready for re-installing it correctly. Finished
the gear shift assembly, dismantled it and primed it to allow for
Went to see Naz today in London to go through the body fitting procedure.
Its worth making sure you follow his instructions implicitly if
you want to get the doors to fit properly. Discovered that an anti-roll
bar is now available, and my A/C system will foul it. Also that
I have installed the front boot liner incorrectly. Moral of the
story is not to assume anything!
Started work on a more robust shift assembly on the gearbox today.
I want to get all the mechanical bits and pieces sorted before I
fit the body.
Installed the fuse box into the front boot liner. Then installed
the boot liner onto the chassis. Discovered that the box of terminals
I have bought are too large to fit the fuse box receptacles. I need
to get some smaller ones tomorrow. Did some more work on the gearbox
Bound the cables for the rear lights and secured them to the chassis.
Also ran cables for the low coolant and fuel sender. Also installed
a longer throw clutch slave push rod as the one supplied with the
slave is too short, picture in the gearbox section. Also installed the ducting for the cabin ventilation, pictures
in the interior section.
Ordered some more split ribbed plastic for wrapping cables in, ducting
for the vents, and ran the cables for the indicators, rear lights
and gearbox speed sender.
Cut the holes in the front bulkhead for the air-conditioning ducts.
Also made an aluminium duct to run the air from the floor vents
into the cabin. Installed the relays and cabling for the heater
and air conditioning system. Tested these out with the nasty supplied
control panel (Which I will be replacing), all the functions work
Wired in the alternator circuit and and ran the main feeds from
battery to the front of the car where the fuse box will go. Pictures
of the battery box in the electrical section.
Major progress today! Engine is running without any faults and firing
on all twelve cylinders. Fault was due to a solder whisker piercing
the insulation of a cable splice I had made.
Doors also arrived today, so I now have all the body components
required to complete the car. Video of engine running to follow
Both DME's are now operational with no error codes, unfortunately
one of the DK motors has a fault which is preventing the engine
from starting. More work required.
Mounted the main engine system relay box, fuse box and all three
ECU's in there new homes. Completed the wiring to the accelerator
pedal sensor and made a bracket to hold the gearshift cables away
from the suggested mounting position as it did not provide enough
movement to get full travel on the cables. Pictures of the fully
wired engine bay and the location of the ECU's in the electrical section.
Spent the day reconnecting the remainder of the engine sensors.
Tidied the cables in the engine bay.
Body has arrived! Along with the order I received one link pipe
(the other requires work), the instruments, lights and switches.
Pictures in the general section
Completed all of the crank sensors, air mass sensors and DME motor
wiring. The engine harness is now fully attached and I can start
the process of feeding the cables to the ignition switch and fuses.
Spoke with Naz today and my body and the other components I have
ordered should arrive Saturday.
Finished wiring the ignition coils and began work on the air mass
sensors, ignition pick ups and the crank shaft sensors. Also wired
up the fuel pumps and checked their operation.
Still wiring. Mounted the ignition coils and cut some more holes
in the bulkhead to pass the cables through correctly. Starting to
get a handle on the remaining connections now.
Got the loom extended now and have the ECU's temporarily positioned.
I need to complete the fuse box side of the engine loom and the
connections to the airflow meters and ignition coils.
Public Service Announcement
Anyone thinking of placing an advert, or renewing their subscription
with KitCar magazine are urged to read this thread on the lamboreplica.co.uk
22nd & 23rd October
Carried on working on the wiring loom.
Measured out the high current battery cables and took the measurements
to my local auto electrician to have them made up. I am using heavier
cables than the original installation, and am also installing a
remote charging socket as the battery is difficult to get to.
Got my battery from Danny today. Its the biggest size that would
fit the battery tray supplied by Parallel. The battery is a 700
Cold Cranking Amp, zero maintenance battery using 'Calcium/Calcium'
technology, whatever that is.
Family matters meant little progress on the car. Managed to begin
work on the wiring loom. This is going to be a long job, so updates
might be a little long in coming.
Installed the second set of manifolds today. Managed to cross thread
one bolt, spent a significant amount of time putting that right.
I hate when a seemingly quick job goes bad.
Installed the first bank of exhaust manifolds tonight on the air-con
pump side. Pictures in the Ancillaries section. Also completed the throttle potentiometer installation,
picture in the electrical section.
You can also see images of my fuel pump installation there.
Finished the fuel pump brackets and run the hoses from the pumps
to the engine. Started work on fitting the manifolds but it looks
like I don't have enough bolts to complete it so I have ordered
Got back from the states today. Naz has delivered my exhaust manifolds
as promised, and they look beautiful. Highly polished stainless
steel really does look the biz. Pictures under Engine -> Ancillaries
Also picked up a Murcielago radio controlled car from a petrol station
on the way back from the airport, Pretty good quality for sixteen
quid. Picture here on this page.
Did some more work on the electrical system. I need to get some
two core plus screen cable to extend the loom back to the passenger
compartment. Unfortunately I will be out of the country for a week
and a half so no more progress until I get back.
Began work on the original BMW cable loom, removing the insulation
tape and rubber. I also began the laborious process of extending
the cables to place the three ECU's into the passenger compartment.
Details in the electrical and engine
Goods news, Parallel are shipping my exhaust manifold today. I also
ordered my remaining lights, electrical components and the body!
Installed the throttle extenders and also installed the intake air
temperature senders. I also started a job I have been meaning to
do in some time. I got the old loom out of storage and started reconnecting
it up to the engine. Pictures to follow shortly.
Got the components back from my local engineering firm for the throttle
body extension pipes. I spent some time welding the components together.
I also reinstalled the clutch and gearbox today.
Received the clutch friction plate back from parallel today. Had
to spend the evening repairing my Nan's washing machine instead
of working on my car.
Received the lights today in the post. The reflectors are nice and
clean, although someone has gone to the trouble of installing shiny
metal foil over the insides of the lamps. I split one of the clusters
and spent an evening removing the foil and the sticky goo used to
attach it from one of the lamps.
Sent the clutch plate away for rework. Started work on the accelerator
Removed the gearbox to get to the clutch friction plate. I need
to send this component back to Parallel so it can be reworked. Cleaned
my workshop up as well because it was starting to get a little dirty
with all the grinding and welding I have been doing of late in there.
Made a small tapped portion of bar which I attached to the top of
the gear knob shifter assembly. I also put a matching thread on
the actual shift rod So that it can be screwed and unscrewed easily.
This is the sort of thing that I feel Parallel should have supplied,
Given the cost of the components, it would make sense for them to
do these two simple jobs. Given the tools I had available, I was
able to do it in about half an hour, But I should think this sort
of thing would be a major inconvenience if you do not have access
to a lathe.
Got a set of Nissan 300zx headlights from ebay with the essential
'E' mark for the SVA. Paid £140 which is a damned sight cheaper
than anywhere else. The diablo with fixed headlights uses the same
headlights as the Nissan 300zx Fairlady. Although Lamborghini uses
an eyebrow of carbon fibre to cover over the Nissan badge.
Completed fabricating the second bracket. This now gives me a forward
and backward motion in the correct direction to provide me a standard
shift pattern at the gear stick. It looks a little bit heath robinson
at the moment, and will require a little bit of tidying up. Good
news being that I can now select gears!
Spoke to Naz today who informs me I should be receiving the exhaust
system including the manifolds in the next couple of weeks. He also
informed me testing of his BMW test chassis revealed a problem with
the clutch friction plate. I need to remove the clutch and send
it back to him for modification. This means I need to remove the
gearbox again, which is a pain to say the least.
Started welding up the second lever arrangement to perform the push-pull
operation on the gear selector shaft. This is a complicated part
so I do not anticipate finishing it until later on this week.
Completed half of the gear selector assembly. Now when you move
the gear stick left and right, it rotates the gear selector shaft
in the relevant directions. Also completed prototyping the mounting
brackets for the selector assembly. I will upload pictures tomorrow.
I spent today making parts for the gear shifter assembly today.
The lathes and milling machines I use are for prototyping small
components, so parts of this size are a little keen for it. I stuck
at it and now have a selector shaft.
Well my internet is back up again. I have been working overseas
for the last few weeks and it looks like I will be away at the end
of september and most of november, so updates once again will not
be at the same rate as before. I will be working on the gear shifter
assembly this weekend, so hopefully I will have some pictures up
9th August 2005
My internet at home is off-line for the minute, so there is not
likely to be any updates for at least a week. Rest assured that
I am still continuing the build, and for those of you using the
site as a build manual, please don't email complaining, I will post
updates and pictures as soon as I can. I am working on the gear-shift
assembly at present, pictures, as always, to follow.
2nd August 2005
Fitted one of the two drive shafts, but was only able to install
the two prop-shaft adapters on the other side as the kit parallel
supplied, did not have enough bolts in it.
1st August 2005
Replaced two of the adjusters on the rear suspension arms. They
had been installed by parallel, but whoever had done it had used
mole grips to tighten them and chewed up the ends. Naz agreed to
replace them, so problem solved.
31st July 2005
Installed the oil-filter housing, oil cooler and associated pipe
work. With these components in place I was able to run a basic compression
check, and ensure that the oil pressure came up. Pictures in the engine section.
30th July 2005
Reworked the engine coolant pipes to accommodate the other engine
components. They route differently to the arrangement on Rover V8
powered replicas, mainly due to the downward angle that the water
pump inlet and outlets are arranged at.
29th July 2005
Work has been pretty hectic recently, so little opportunity to work
on the car. Began working on the fuel pump assembly. It needs to
fit in quite a small space between the fuel tank and engine underneath
the passenger side engine mount. I made two brackets to hold it,
but one is too wide and so it needs some rework.
24th July 2005
Despite a few interruptions, I managed to adjust the inside of the
bell housing so that the clutch was able to rotate freely. I also
mated the engine to the gearbox, and installed the pair into the
chassis, freeing up lots of valuable floor space! Pictures in the chassis section.
23rd July 2005
Spent most of the day adjusting the starter motor aperture on the
gearbox adapter as it wasn't big enough for my particular starter
motor. Also installed the custom flywheel and clutch components.
Pictures in the gearbox section.
22nd July 2005
Installed the flywheel and attempted to install the clutch. However
the gearbox adapter plate has a problem with regards to the starter
motor.Not sure if its my starter motor location or type that's causing
the problem, but basically I need to relieve some metal from the
adapter plate before I can assemble the rest of the components.
Pictures in the engine Ancillaries section.
21st July 2005
Ran the hydraulic line for the clutch. I also fitted the replacement
manifold to the air conditioning compressor. This is much easier
to do at this stage than later on when the engine is installed.
I also fitted a new clutch release bearing. You ought to do this
even if you are not sure your old one is damaged. The cost of this
part is trivial compared to the time and effort required to change
it three months later. Be aware that the engine adapter and clutch
does not come with any bolts or a release bearing, you will have
to source these yourself.
19th July 2005
Received all of the final components bar the exhaust system. I will
soon be able to begin installing the engine and gearbox. There are
a few jobs left to complete before this can happen.
18th July 2005
Received my 12 circuit fuse box from NF Auto Development. I can
save myself significant money running the cables myself than buying
a ready made loom. Because a significant chunk of my wiring comes
from the donor BMW, it makes sense to adapt that than buy another
loom and hack that apart to suit.
12th July 2005
Got a phone call today from Naz, that the rest of my parts bar my
clutch are ready. They should be delivered in the next few days.
This means I can finish running my clutch lines and heater hoses.
Once this is done, I can locate the engine and begin fitting the
engine management computers and sorting out the electrics.
11th July 2005
Bonded the bulkhead panels to the chassis today using Tiger-Seal.
I was fairly generous with its application and managed to go through
almost an entire tube completing this job. Buy the tubes as you
need them as they have a very limited shelf life.
10th July 2005
I have managed to make significant progress today. I have run the
air conditioning pipes, fitted the air-con drier, battery tray and
also dry-fitted the front bulkhead fibre glass panels. Details and
pictures as always in the chassis section.
8th July 2005
Installed the evaporator/heater box into the space between the steering
rack and the front bulkhead. I used some 3mm aluminium sheet cut
into strips and bent up at the relevant angles. It takes a little
amount of fiddling about to get the brackets in the right place,
but its worth taking the time to secure it right because it will
be a bitch to get to once the body is fitted. Pictures in the chassis section.
1st July 2005
Installed the air conditioning radiator today. I fabricated brackets
from stainless steel angle bar, and secured the brackets to the
chassis with some wurth self tapping screws. The placement of this
radiator is critical because if it is too high, it will foul the
body. Too low and it will be difficult to remove the oil filter
from the remote housing. As it happens, it looks like I have a different
type of oil filter housing to that normally found in these type
of replicas. Mine is quite a bit taller, so I will have this problem
whatever. Some more clever bracketry may be required. Pictures to
29th June 2005
Completed running the vacuum hose from the front brake servo to
the engine compartment. Also torqued the crankshaft bolt which holds
the vibrational damper on the engine. I have only done it now as
I had to search around and find someone who could lend me a torque
wrench that would go up to the massive torque required. This bolt
needs to be tightened to 440 Nm, the wrench I used was six feet
long! Pictures to follow soon.
27th June 2005
Ran the rear brake pipes this evening. I had a total of three inches
remaining from the reel supplied by parallel designs. I did however
run out of p-clips, so I will need to order some more before I finish
the clutch and vacuum lines. More details in the chassis section.
26th June 2005
Cant believe its been three weeks since I touched the car last.
I had been out of the country for two weeks and other things just
seemed to keep on getting in the way of me doing any work on the
car. Still back at it today, I fitted the brake pipes to the front
wheels, and will complete the rear wheels later on in the week.
Updates to the chassis section. Had a
head scratching session today with the air con unit, mine does not
seem to fit..
5th June 2005
Hard at it today. Fitted the radiators, cooling pipes, pedal boxes,
clutch master, brake master and servo. Pictures in the relevant
4th June 2005
Been a bit quiet recently. Busy with work amongst other things.
Although I had the chassis delivered, I could not really do a lot
as I didn't have any of the 'joining bits'. Well I took a trip down
to South London today to pick up the cooling, air con, brake, engine
mounts, gearbox mounts and pedal box components. I am still missing
my clutch, gear shifter assembly, drive shafts and air con compressor
manifold. I also dropped my oil lines off for Naz to modify so that
I can use an oil cooler as the oil receives no direct ventilation
in the diablo as it would in the original donor vehicle.
24th May 2005
Transported my engine back from Danny's workshop today with the
help of a trailer I borrowed from my friend Terry. It bounced around
a bit but I secured it with plenty of straps to stop it falling
21st May 2005
Removed the engine from the engine stand and fabricated a wooden
cradle to transport it back to my workshop. Also figured out a way
to drive the alternator using only the original BMW idler rather
than having to make a replacement pulley arrangement for the power
steering pump. Pictures to follow shortly.
17th May 2005
More good news. Today I sold my Chrysler grand voyager, freeing
up some more cash for diablo bits and pieces.
14th May 2005
Woohoo! Chassis arrived today. Delivered by a very nice man, although
a little bit earlier in the day than Naz at PD had mentioned (8:30am
rather than 10am), but otherwise made up. After much chin rubbing,
grunting and straining, realized that the handbrake was still on,
at which point wheeling it into the workshop became a rather much
easier affair... Pictures in the workshop and chassis section.
12th May 2005
Good news! My chassis will be delivered on saturday. The clutch will arrive later but at least I can make a start on
fitting the engine.
7th May 2005
Fitted the inlet manifolds to the engine. Also test fitted the throttle
bodies but have encountered a minor problem. The oil filler pipe
fouls the throttle motors. I will need to fabricate spacers or to
see if the air boxes will fit close to the bulkhead. I have fitted
the throttle motors temporarily. Pictures in the engine section.
6th May 2005
Completed the inlet manifolds today. Pictures in the misc section under body. Practical reasons forced me to finish the manifolds
in the way that I have, mainly I could not get our CNC machine to
fabricate a plate of the dimensions required.
Also reorganized the engine section as it was getting too big and
cumbersome all in one page.
1st May 2005
Attended the Stoneleigh kit car show today. Met with Naz from Parallel
designs and after some discussion, ordered my chassis! Also met
some of the boys from lamboreplica.co.uk.
Pictures of diablo's and the stands from the show can be seen in
the miscellaneous section.
25th April 2005
I brought the gearbox home from Danny's garage today and wheeled
it into the workshop at home in a wheel barrow.
23rd April 2005
Bead blasted the gearbox today. It looks brand new now. Pictures
to follow as I left my camera at work. Updated the gearbox page
with data supplied by Neil, Thanks mate!
22nd April 2005
I've reached the end of my tether trying to clean the inlet manifolds.
The manifolds are stained and no chemical treatment or amount of
sand blasting seems to shift it. So I have decided to simply paint
them. They will not look as I intended, I will need to rethink the
lamborghini logo I intend to use.
21st April 2005
We had a new, much larger bead blaster arrive at work. I was able
to give the inlet manifolds a thorough cleaning. I will need to
make sure I remove all traces of glass beads before reinstalling
them, as I don't want any debris getting into the combustion chambers.
Also added a gearbox section as the engine page is large enough
already. Also updated the gearbox ratio's under the resources page
as I got more accurate figures today.
16th April 2005
Cleaned all the grime from the gearbox, but could not find and method
of removing the staining and corrosion from the box. Also calculated
the gearbox ratios which are in the resource section.
14th April 2005
Not much has happened last week, so updates have been a little less
regular than usual. My gearbox arrived today, I need to give it
a damned good clean because its pretty dirty. Details in the engine
12th April 2005
Cleaned the air conditioning pump. I thought it was painted black,
it turned out it was just really dirty. Pictures in the engine section.
5th April 2005
I completed the rest of the engine work today. The sump, oil pump
and alternator as well as drive belt tensioners, crank position
sensors and pulleys have all now been installed. I also cleaned
up the injectors, more on this in the electrical section.
4th April 2005
Took the day off work today and made major progress. The engine
is mostly assembled. There are a few jobs remaining, including fitting
the oil and water pumps, but everything else is complete. Check
the engine section for details.
2nd April 2005
Installed the first cylinder head and the sump. Also replaced the
big-end bearing shells. The sump pan must be re-installed to fit
the timing pin which locks the flywheel.
1st April 2005
Manufactured a tool to lock the flywheel in the correct position.
This is required to install the heads and timing chain correctly.
31 March 2005
Took measurements for the engine timing pin which I will make tomorrow
at work. Also dropped off the cleaned engine components at the workshop
so that I am ready for the weekend. Also updated the web site to
include engine torque settings which can be found here
29 March 2005
Big end shells arrived from germany today. Comparison with the original
items indicate I have got the right thing.
26 March 2005
Cleaned the heads mating surfaces and finished making the second
timing clamp. I can now refit the heads as soon as the big end bearing
21 March 2005
I have ordered the replacement bearing shells. These are coming
from germany and should be here in seven to ten days.
20 March 2005
Finished the design for the inlet manifold covers. You can download
the design for these from the resources section.
19 March 2005
Cleaned all the pistons up and installed the new rings. I had a
good chance to investigate the bottom end and have decided to order
a set of shells for the con rods. Some of the shells had inclusions
in the metal and two had significant wear on the surface, enough
to warrant replacement. The crankshaft itself is mirror finish so
I am just going to put new standard size shells in. Forgot my camera
so no new pics today.
18 March 2005
The guy who was going to buy my chrysler voyager decided to start
messing me about today. Wanted to take the vehicle and pay me next
week! So its going on ebay in the next few days. Looks like I will
have to wait a bit before ordering my chassis. Almost finished the
inlet manifold cover plates. Check back later in the week for details.
16 March 2005
Reassembled the alternator. Dropped the inlet manifolds off at my
local engineering company to have the BMW logo milled off of them.
I will make new plates which will bolt to the manifolds with the
lamborghini logo on them.
15 March 2005
Painted the laminate plates around the field winding on the alternator
today. I painted it yellow because that's the colour the car is
going. Also checked the modified clamp and it worked perfectly.
14 March 2005
Sandblasted the alternator housings today at work. But forgot to
bring them home. Manufactured a cam shaft locking tool. A few minor
modifications are required but it seems to work alright. Two of
these are required to hold both camshafts while tensioning the timing
chain. I will make the second one when the first one fits perfectly.
You can download the mechanical diagram for this component in the resource section.
13 March 2005
Dismantled the alternator today, and put the bits in the dish washer. I thought the alternator was pretty
clean when I pulled the engine out, I have since changed my mind.
Brushes on the alternator look pretty worn, but they should be OK
for the time being. While removing the front pulley from the alternator,
I managed to damage it. Be very careful with this part as it is
very soft aluminium. If you damage it, the belt which runs on this
pulley will be knackered in no time. Looks like I will need to buy
12 March 2005
Completed the right hand bank cylinder head. The inlet valves required
very little re grinding, but the exhaust valves required a lot more
elbow grease. Just waiting for the piston rings before putting it
all back together. Dismantled the alternator for cleaning.
11 March 2005
Sandblasted the alternator mounting bracket today. I pushed blu-tak
into the oil ports to stop the sand damaging the seals here, and
used sellotape to mask off the oil feed mounting plates. This item
was particularly filthy and took a lot of cleaning. I was hoping
to machine a camshaft locking tool today, but ran out of time at
10 March 2005
Measured up the head for a camshaft locking tool. You will need
two of these to correctly time the engine as well as a crankshaft
locking pin. I have drawn up some of the tools using a CAD program,
and will post the design just as soon as I am sure it will work.
8 March 2005
Dismantled and cleaned the water pump, alternator and AC compressor
idlers and tensioners. The idlers could probably do with replacing
as they seem to be a little noisy. The bearings are sealed and I
am going to investigate the possibility of re greasing them in some
way as they are very expensive to replace.
6 March 2005
Cleaned and repainted the valve covers and engine sump. They look
much better now. These are the only parts of the engine that I will
be repainting as I want to keep the engine looking as a production
engine would look. I chose silver for these parts as this was the
colour they were originally. The colour is not a close match, but
the old paint was heavily stained and discolored anyway, so who
knows, it might be pretty close.
5 March 2005
Overhauled the left hand bank cylinder head. This involves stripping
the camshaft out, de-coke the valves, fit new oil stem seals and
regrind the valves back into their seats.
1 March 2005
Ordered a water pump, head gaskets and piston rings. The water pump
is ordered on an exchange basis from BMW. You get some of your money
back when you take in your old pump.
26 Feb 2005
Finished overhauling the DK Motors today. I now have a pair of shiny
DKM's that are in perfect working order. The difference in operating
force is noticeable, and the motors spring back quickly and without
hesitation. I also completed cleaning the engine block and heads
down at Danny's yard. I brought a whole load of stuff back home
25 Feb 2005
Began overhauling the DK Motors. These are basically very large
servo motors, and are extremely expensive to replace. Overhauling
these is simple and an evenings work, details in the electrical
24 Feb. 2005
Ordered the engine gasket set from BMW today. After much ringing
around for various prices ranging from the astronomic to the outrageous,
the cheapest price I got was from BMW themselves. The price for
the set was £211 and some pence, half the price of pattern
parts. The set excludes the intake manifold rubber gaskets and
head gaskets themselves.
23 Feb. 2005
A BMW specialist picked up the stripped body shell of my donor car
today. There was much grumbling about the car from the guy picking
it up about it having nothing worth selling on it, I pointed out
it had a fully functional automatic gearbox and leather interior.
Cash changed hands and it was gone. I had stripped it fairly well
with the intention of recovering some of the cost of the car via
ebay. I was in two minds about keeping the alloy wheels from the
BMW as they would provide a nice temporary way of moving the car
around, but Danny has a nice set of illegal tyres on 5x120mm steel
wheels he has given me so this has solved that problem.
21 Feb. 2005
Left the timing case covers and associated components soaking in
diesel/petrol mix for the week. This should help remove the hard
oil deposits and mean that less aggressive cleaning methods can
be employed by the weekend. I will use my kärcher pressure
washer to remove all the stubborn crud from the hard to reach places.
I tested some alloy wheel cleaner on the outside of the block,
it came up like new. I want to make the engine look factory. I
don't like painted blocks, they look good for a while up until
starts to flake off.
19 Feb 2005
Removed the heads from the engine and began cleaning the block.
The bores showed no wear whatsoever. One bore has what appears to
be a black score mark, but this cylinder tested fine for compression.
I cant feel it with my fingernail, so its probably just discoloration.
The thing is I don't remember it being there when I removed the
cylinder head originally. The black gunk was restricted to the interior
of the timing cover only, so cleaning shouldn't take too long. Photos
to follow shortly in the engine section.
12 Feb 2005
Removed the throttle potentiometer and the fuel pumps from the donor
car. The throttle pot is an absolute mare to remove, with the aid
of careful persuasion from a crowbar, I was able to remove it without
any damage. It looks to me that most of the steering column would
need to be removed to do it 'by the book'.
11 Feb 2005
Hoisted the engine clear of the donor car today and got it mounted
on the engine stand. Its a very heavy engine for the stand I have
bought, so I have to be careful wheeling it around, lest it topple
over. All of the engine cleaning work that needs to be done will
be completed at Danny's workshop so I can wheel a fully dressed
and ready to fit engine into my workshop.
10 Feb 2005
Took the next two days off work to remove the engine and other bits
from the BMW. Danny has kindly provided me with a bay in his workshop,
and use of his extensive tool chest. Began today by removing all
the ancillaries from the engine and carefully disconnecting the
engine wiring from the rest of the car.
6 Feb 2005
Put the final coat on the workshop floor. I used quite a bit of
paint doing it, might be a bit thick in places. The tin says two
days before it is safe to walk on, I will allow till thursday before
trying it out. I have organized with Danny, and I will be taking
the BMW up to his garage on thursday to remove the engine, ready
for cleaning up and overhaul. My Dad has also dropped around some
spare strip lights I can install if I need more light.
I have updated the engine section with some general information
concerning the BMW M70 V12.
3 Feb 2005
Painted the other half of the workshop floor. By the weekend, I
should be able to complete the second and final coat. The provides
a water and oil proof layer which should make clearing up an awful
lot easier. The effort taken prior to this is starting to show through
now, I have a very flat workshop floor which should be quite easy
to use things like trolley jacks etc on. I also picked up a wooden
desk from work which was being thrown out. It was a fake leather
top which is nice and easy to clean down, and under drawers for
storing bits and pieces in.
2 Feb 2005
Moved all the junk from the unpainted half of the workshop out.
Also installed a fold away work bench which I can put my Mac tools
31 Jan 2005
Painted the edges and one half of the workshop floor with the first
coat of epoxy floor paint. It dries to walk on in two days, and
is solid in five. Its touch dry within about 6 hours. I would have
painted more, but I had quite a lot of junk to move out to another
shed before I could do the other half.
30 Jan 2005
Sealed the workshop floor with a mix of 5 parts water to 1 part
PVA. Stops all sorts of problems with the top layer of cement dusting,
and provides a good key for the epoxy paint to adhere to.
23 Jan 2005
Felt is all placed correctly now, thanks to Gary, and the trims
have been added. These make it look nice and stop the wind getting
up underneath the felt and lifting it again. Externally its almost
19 Jan 2005
Went out into the garden today and saw some of the felt flapping
about in the wind. Nailed it down temporarily until sunday when
Gary will be coming again to help me finish it off. I will need
to replace a section and finish the edges off to stop this from
happening again. Started doing the schematics for the engine management
16 Jan 2005
Finished painting the workshop walls. I have painted them white
to keep the dust from the cement blocks and mortar down to a minimum.
Also white walls reflect light better. The floors will be sealed
to also stop them generating dust. I have not yet decided on a finish
for the floor yet.
15 Jan 2005
Started fiddling with the on-board computers. I was worried that
the engine management system would place the engine into limp-home
mode if any of the other computers were disconnected. All of the
computers are linked, and as I am only using the three engine computers,
I needed to make sure they worked with all the other stuff disconnected.
The good news is the engine runs fine without the ABS & Traction
control computer disconnected, with no engine management errors.
Now I need to remove the transmission control computer to confirm
my belief that it is possible to reuse the engine management system
rather than having to buy a third party system. A full schematic
of the proposed system will be forthcoming soon.
12 Jan 2005
Picked up the first major component of the car, the engine donor.
The car is a 1990 BMW 750iL. I wanted to buy a complete car so that
I could hear the engine running. You can see some pictures of the
car under 'Donor Car'. There seems to be
no major faults with car, it still has tax and MOT remaining. I
was therefore able to drive it from Peterborough to my home, a distance
of some 100 miles with no problems whatsoever.
2 Jan 2005
Almost finished my workshop now. Felted the roof with a friends
help (Cheers Gary), all that needs to happen now is for me to seal
the concrete floor, paint the walls and to trim the outside felting
so that it looks nice. Photos of current progress are available here