ZERO Build

[Boffy]

Picked up the frame yesterday, looks a nice job, sand blasted, zinc coated and powder coated.

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[Boffy]

Couldn't wait to get started so fitted the diff, heavy sucker when your doing it on your own, anyway, with a bit of ingenuity and a few bits of wood it went in.

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[Boffy]

Phew, nearly finished
Dry fit of a few panels to see if anything needs adjusting, not a bad fit, now need to clean the cuts up a bit and them mark it out for drilling and rivets etc.

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[Boffy]

Filter & Pump fitted using the infamous DIY Rivnut Tool (patent pending).
Just need to straighten it up and tighten down the screws etc.

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[Boffy]

Started to fit the panels, just drilling and pinning at the moment, once I have as many panels done as I can I will glue and Rivet, thought about using the wife's scone mix, that sticks to everything and will never come off

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[Boffy]

Internal side panels & passenger tunnel & footwell panels drilled and pinned, wish I had more pins they are fantastic.

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[Boffy]

All internal & external panels drilled, that's a lot of holes
Next job will be to glue & rivet the rear panel and sides, will leave the tunnel until I have run cables etc etc.

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[Boffy]

Its been an interesting weekend, first job was to fit the rear wishbones, upper one first which consists of the following:

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first job was to clean out the centre of the tubes to take the bush's, no drama with that, cleaned out, coated the inside if the tube with copper grease and with a bolt, nut & couple of washers wound in all the bush's.
Then cleaned up the tubes and inserted inside the bush's, all was going so well.
Then its time to fit, so for each connection I need a bolt, two small washers, large washer & nut, the small washers are to go between the bush/inner tube and the bracket, I offer up the wishbone and figure there is no way I will get a washer down the side of the bush, ............crap, what now.
Cup of tea later and I had a brainstorm, cant shorten the wishbone so need to open the brackets by a couple of mill, so, with a bolt, two nuts and a couple of washers I had a tool that I could put in between the bracket, tighten the nut and it would open up the bracket just enough for me to slot in the washers.

[Boffy]

Second job, fit the drive shafts, offer up the first one and it doesnt quite go all the way into the diff but will bolt up to the wishbone bracket.
Offer up the second shaft and it slots all the way into the diff, however it sticks out way past the wishbone bracket.
Crap, whats wrong, decided to measure the distance from the center of the diff to the brackets, its about 30mm out so I figure its a complete mess and should grab the petrol can and set light to it.
Decided a cup of tea was required.
Another brainstorm, I couldnt believe the diff was that far out so took the tray off the back and tada, the measurement point I assumed was the middle of the diff wasnt, measured it again from the true centre and its within a mill so happy about that. Next the shafts, maybe they are handed and I have them the wrong way round, swapped them over and tada, bloody great.
Just need to drill out the bolt holes as they are slightly off, hopefully they will then all bolt up and I can move on.

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[Boffy]

Third job, get the tires on the wheels, or is it get the wheels on the tires.

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