Front brake lines

Yesterday I fitted the front brake lines. They all seemed to go in quite easily but think the passenger side is too long, will have to check before I go any further as the brakes are one thing I don't want to mess up!

Fuel system

Today I tackled the fuel system. As I had no instructions I made a diagram and checked with GBS that it was correct before I started anything. Turns out I was correct so made a start X 

That's the diagram I'm going by. 

I now have the swirl pot in, low pressure pump, highly pressure pump and filter.

Some big jobs done

So today I got into the garage for a few hours and finally fixed the first few panels into the car. They were drilled, cleaned up and then a bead of polyurethane sealant added before they were riveted in place. 

Doesn't look a lot but took its time as usual as I want it all right. It's starting to take shape now and look sort of like a car.

At the end I put the dash on just to see what it looked like. 😀

A few too many rivets I think. Have used much less on other panels.

Brake line covers

Just a quick job to finish off today, I put a bit of plastic tubing over the brake lines on any exposed areas to protect them from chaffing. 

Scuttle

Today it was far too cold and windy to be in the garage (and I've git no electricity in there) so decided to tackle the scuttle.

I first cleared the few mm of burnt plastic from the edges of the panels I needed. Then clamped them into my "works bench" (aka table tennis table) and began to drill and Cleco it together. It was all really straight forwards and went together well, the only thing I'd do differently is I would do the front and rear panels at the same time to aid with holding the top piece in place. It was rather flimsy until it was riveted but now a sturdy item.

All I need to do now is some black glue around the joints and then remove the tabs and parts of the rivets. 

Handbrake and cable in place

Spent a few hours in the garage today and started by torquing up the bolts on the diff and the prop shaft.

After that I fitted the handbrake and handbrake cable. It was fairly straight forwards however the micro switch doesn't work on the handbrake so will need to adjust it.

Fuel pump fitted

For the first time in weeks I've found time to get out to the garage. I spent about 3 hours today fitting the fuel pump plate, finishing the footwell panels and made a start on the back panel. 

There is a weather warning out tomorrow so might not spend it in the garage but will get the panels riveted on if I get a chance. 

This is the fuel pump plate held in place with 4 rivnuts.

And the pump and filter all in place.

And here is the rear panel and footwell panels held in place with clecos ready for tomorrow.

Footwell panels

After sorting the roof I set about getting the footwell panels ready for fitting. So I measured up the centre line of the chassis and drew a straight line down the panel where this would centre my rivets. Then I put evenly spaced marks down the line and drilled them out. I deburred each hole with a 7mm drill bit and then positioned it on the chassis.

I drilled through the first hole and held it in place with a Cleco before continuing with the rest and adding more clecos as I went. 

I then started on the passenger side but the drill died halfway through and it was freezing so stopped for the day. 

Once I've got the passenger panel ready and the back panel I will add the sealant and get them in place.

Took about 3 hours today.

Fixing the garage

It was the first time that I went into the garage today after it raining the night before. Turns out that the roof still isn't completely waterproof so set about sorting it. I put a clear tarpaulin up and zip tied it to the roof cross members - it should now be sorted. 

Being an asbestos roof I couldn't play with it! 

Differential fitted

Today was a job that needed doing early in the build and ideally with someone to help but I didn't have anyone so struggled on alone. I used a ratchet strap to help hold it while I got the first bolt in. After that it was plain sailing. With the planning and prep work included it took about an hour in total. 

Trial fitted some panels

After fitting my pedals I had a play with my body panels and trial fitted a few just to see how it would look. I think things will come on quickly once I fit them for real. 

Pedals fitted

After fitting countless bushes to the wishbones I decided to fit them to the pedals and then get the pedals on the car. It was fairly simple, bushes fitted the same and there were two that needed fitting into the chassis itself. Given how awkward they are in the wishbones I didn't relish the task but they slipped in much easier so think the holes are ever so slightly bigger. 

After the bushes were fitted it was a simple case of fitting the metal tube through the middle and bolting together. The pedals moved together until the bolt was tightened up and now it all works perfectly. Maybe a bit stiff but I'm sure it will loosen up over time with use.

May need to cut the bolt down slightly but awaiting confirmation from GBS.

Suspension bushes in

Due to the lack of fitting kits (that I forgot to order) I've decided to make a start on fitting the suspension bushes. Basically you need to clean out any powder coating from the wishbones, give it a good coating of copper slip and the same with the nylon top hats. Then using a vice slowly and squarely squash them in. Once both sides are in, insert the metal tube (which is what the bolts pivot on) and again force it home with the vice. Quite simple but very time consuming. So far has taken about 4 hours and only just finished the front!

Steering Bung

Not really much to say on this but it was the first part I assembled and put on the car so thought it worth a mention.

Simply assemble the three parts and slide them into the hole on the chassis - easy.

First jobs...

So after unpacking and putting my parts in a mixture of the garage and the spare room (very understanding wife) I set about starting with my first few jobs, turns out though that I hadn't ordered any sealant, rivets or nuts and bolts to fit various parts. But of a shame but will order on Monday. 

Collected the kit

This weekend my wife and I hired a van and took the long journey up to GBS to collect my long awaited toy. We were greated with a cup of tea and then set about accounting for all the parts. Wasn't a huge initial order but enough to keep me going for a while at least. 😀

 

Differential acquired

So after much searching on eBay I finally found a differential that was not only on budget but also reconditioned! Looking to collect it at the end of the week and at only £125 it was a good buy (subject to checking it over). It's a 3.92:1 ratio so should be ok for what I am going to use the car for. 

Ordered!!

A few days ago I made the order for my GBS Zero. I went for the normal chassis (not the wide body) and after discussion with Wayne (salesman) I went for the Ford build not the Mazda as I initially intended. This is due to the Mazda build using an old engine and drivetrain which may have problems in the future, the Ford will have a new engine so less problems long term.

Ive ordered the starter kit in Kawasaki Green with Cobra hoops. Everything is powder-coated and ordered the brake lines, handbrake, wiring loom, fuel tank and a few other bits too. I did want to go for the full rolling chassis initially, but couldn't stretch to it so had to cut back on some parts for now. There are only a few big outlays in this build that I can think of: 1. The initial kit and 2. The engine/gearbox/ECU kit, everything else is all small(ish) parts that I will buy as I need them.

My chassis is now in production and looking to collect at the end of September.

A bit of background

Well that worked and now I've got the time set to UK I'm good to go!

So where to start?

Firstly a bit about me. Im 30 years old and a serving soldier. I enjoy building things - anything - and have done loads of projects in the past from electronics, to bird houses to a radio controlled go kart for my little nephew.


While looking for something new and challenging the wife (yes she is one top wife) suggested a kit car.

So after about 18 months of saving, researching, visiting shows and reading magazines I finally decided which car I wanted. As you can tell from the title of the blog, I settled on the GBS Zero. There are many reasons for it - price, down to earth sales people, great blogs and great reviews just to name a few.

Blog is up and running

So I'm not a fan of social media and don't do Facebook and all the other bits so this is new to me. Hopefully this works and will be able to keep a detailed log of my car build as I do it.