Well i have been without my own form of transport until today (17th July) as my sister has been away on a work placement and took the car with her! All this has meant is that things have not progressed as quickly as they could have. That said, they have gone fairly well!
Floor
The first job was to fit the floor. However remember to drill the rivet holes for the transmission tunnel and bulkhead panels first as its a hell of a lot easier. Eventually I got around to fitting the floor. I turned the chassis over and placed the floor on. Drew around the tubes then flipped the floor over and drilled through. Just as well the GTS chassis is well made and symmetrical! The floor was then removed again and the tubes covered with sikaflex then the floor was riveted on. I only used a normal rivet gun, and got on fine, probably about 120 rivets in the floor, so my arms were a bit tired, but its not coming off in a hurry!
Brake lines and Master Cylinder
The next job was to fit the master cylinder. This was a bit of a challenge as the hole in the bulkhead wasnt big enough, however this was fixed with a file and a bit of sweat. The holes were then spotted through the master cylinder and drilled, then it was bolted in.
After this came the job of routing the brake lines. At this stage it wasnt too much of a problem. My master cylinder has 2 outlets for the front brakes, and one for the rear brakes. The line from the bottom of the cylinder, going to the front brakes was a bit tight, but I managed to squeeze it in without it touching the chassis. The rear line was run down the top drivers side of the transmission tunnel and P-clipped with stainless and rubber P-clips. These were placed around every 200mm or so. Fitting the rear line into it bracket was a fun job, and was actually done after the diff was fitted to avoid damaging it. It goes under the central bulkhead tube, and up into the bottom of the bracket to join onto the male bulkhead fitting on the end of the flexi line. The braket was made from 2mm aluminium and rivited and sikaflexed to the chassis. All of this represents about half a days work.
Differential and Rear Suspension
The diff was hoisted into the chassis between 2 people and bolted in place with 2 bits of M12 studding. The de dion axle was then fitted. I had already bolted the trailing arms to the axle, and it will still fit through the chassis. Although this did take 3 people in total. 2 to hold the axle, and one to shove the bolts in. It worked though, and beat trying to fit all the trailing arms once the axles in the chassis. The shocks needed spacers making and fitting, there were made from 30mm with a 12mm hole in. The panhard rod also needed a spacer as it fouled the axle which was a small problem.
Infill Panels
These are a nightmare to get the right shape and size. I used the CAD plans of the chassis in the end. I fitted them slightly differently to the way suggested in the build manual, as my way seemed easier and a bit neater. They were drilled and rivited, along with being stuck with PU adhesive.
Side Panels
These were a bit of a nightmare, and I am very grateful for my dads help in fitting these. They arent finished in these pictures, but they only need the tops trimming now, the steering rack holes drilled and the wishbone holes opening out a bit more. I fitted the rear of the panel first, leaving the panel to the length that it was supplied (i.e. too long) then I marked out for the headlight brackets, then the upper wishbone brackets and finally the lower wishbone backets. Its going to have taken 2 days to trim and fit the panels, and I will be glad when its all over.
The GTS bodywork is excellent, the finish is very good, needing only a quick polish to bring the panels up to a fabulous shine. They are a good fit on the chassis and the nose/scuttle/bonnet all line up perfectly with the side panels. Obviously a lot of thought has gone into the design of the panels.
The next job is to finish the side panels, then fit the front suspension and get the wheels on. Then at last it will be a rolling chassis!
