ZERO Build

For keeping us up dated on your building of a Clubbie/Seven replica

Moderators: Simjen, KiwiBirkin

Forum rules
User's Projects / Build Ups Forum Rules
This section of where you guys can show off the progress you make as your build comes together of your clubman, give details of any modification progress, share pictures etc. There are just a few rules that need to be followed for this forum to stay nice, clean and easy to use:

1. ONE thread per project please. You all have access to edit your own posts, so do that. You may post as many times as you feel like it within your allocated thread.
2. Only the person who owns the thread may post in it. Any others will be deleted. If you want to ask questions, comment or start a discussion, start a thread in the Project Discussion section or use the private message function.
3. You may not use your thread for anything else apart from showing off your car and it's build process, use the other forums for this.
4. Thread titles must be include your user name and a little about the project please.

Important : As this was a exsisting forum moved to its new home all exsisting build diarys will carry on as they are but by the new rules

Cheers Stephen
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Boffy
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Location: Unsworth Heights, North Shore

Re: ZERO Build

Post by Boffy » Tue Nov 01, 2011 6:11 pm

Picked up the frame yesterday, looks a nice job, sand blasted, zinc coated and powder coated.
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Boffy
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Re: ZERO Build

Post by Boffy » Tue Nov 01, 2011 6:14 pm

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
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Re: ZERO Build

Post by Boffy » Wed Nov 02, 2011 6:16 pm

Phew, nearly finished :lol:
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
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Location: Unsworth Heights, North Shore

Re: ZERO Build

Post by Boffy » Sat Nov 05, 2011 4:30 pm

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
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Re: ZERO Build

Post by Boffy » Sat Nov 05, 2011 4:34 pm

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 :lol:
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Boffy
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Location: Unsworth Heights, North Shore

Re: ZERO Build

Post by Boffy » Sun Nov 06, 2011 2:18 pm

Internal side panels & passenger tunnel & footwell panels drilled and pinned, wish I had more pins they are fantastic.
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Boffy
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Location: Unsworth Heights, North Shore

Re: ZERO Build

Post by Boffy » Sun Nov 13, 2011 3:38 pm

All internal & external panels drilled, that's a lot of holes :o
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
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Re: ZERO Build

Post by Boffy » Sun Nov 20, 2011 3:37 pm

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.

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Boffy
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Re: ZERO Build

Post by Boffy » Sun Nov 20, 2011 3:47 pm

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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Last edited by Boffy on Mon Nov 21, 2011 2:13 pm, edited 1 time in total.

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Boffy
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Posts: 210
Joined: Sun Feb 20, 2011 2:10 pm
Location: Unsworth Heights, North Shore

Re: ZERO Build

Post by Boffy » Sun Nov 20, 2011 3:48 pm

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