Build Process


I intend to follow this framework of build, no doubt the sequence will change but as a starter it seems (well on paper anyway!) a logical progression

Revision 9 3 October 2016

Chassis  (on stands) Started Done
1 Steering column bush kit, test fit column 21.12.14
2 Clean out seat belt mounting threads  21.12.14
3 Pedal box, dry fit brake and clutch 11.01.15
4 Paint differential 22.01.15
Fit differential 29.03.15
5 Panel: Drivers footwell Panel 08.02.15
Panel: Passenger footwell Panel 08.02.15
Panel: Driver footwell side Panel 26.02.15
Panel: Passenger footwell side Panel 26.02.15
6 Master Cylinder 15.02.15
Fork end/Pin Pedal to M Cylinder 15.02.15
7 Brake lines Rear Front 09.04.15
8 Chassis loom 14.06.15
9 Panel: Seat back 12.07.15
10 Fix gearbox mounting rubber 04.03.15
11 Panel: Drivers side tunnel 12.07.15
12 Low pressure fuel circuit Front Back 22.05.15
13 Swirl pot & bracket 18.03.15
14 High pressure fuel pump 10.05.15
15 Low pressure fuel pump/filter 26.04.15
16 Hand brake & handbrake lines 03.04.15
17 Steering rack  11.10.15
18 Steering shaft / steeering column 25.02.18
19 Panel: Drivers side crescent 06.09.15
20 Panel: Passenger side crescent 06.09.15
21 Rear suspension 07.06.15
22 Rear shafts 27.02.16
23 Rear Shock absorbers 26.07.15
24 Front suspension - remember IVA boots 22.08.15
26 Prop shaft 11.11.15
27 Panel: Passenger side tunnel 10.12.15
28 Speed sensor bracket 29.11.15
29 Clean & mount fuel tank 12.05.16
30 Panel: nearside side panels 11.11.15
31 Panel: offside side panels  13.11.15
32 Carpet - O/S, Floors & footwells 11.09.15
33 Carpets - Seat back panel, tunnel sides 27.12.15
34 Construct Scuttle / firewall - part 1 09.01.16
35 Finalise Scuttle / firewall - part 2 30.01.16
36 Dry fit Battery tray & pedal box cover 30.01.16
37 Rear Panel  10.07.16
38 Rear discs, calipers  17.04.16
Engine Prep and install
1 Replace sump 23.07.17
2 Thrust bearing/spigot 19.11.16
3 Remove inlet manifold 10.11.16
4 Remove exhaust manifold 10.11.16
5 Remove thermostat housing 10.11.16
6 Gerbox prep (bellhousing, reverse switch, clutch fork) 07.01.17
7 Engine to gearbox dowls 02.08.17
8 Mount gearbox to engine 02.08.17
9 Mount starter motor to engine/gearbox 16.08.17
10 Oil pressure sensor
11 Engine mountings 27.08.17
12 Install Engine/Gearbox combination  27.08.17
Engine Services
1 Plenum/Injectors and Air intake 11.03.18
2 High pressure fuel circuit 02.04.18
3 Alternator 11.09.17
4 Engine Loom 22.11.17
5 Engine earth strap 06.12.17
6 Horn  26.10.17
7 Radiator 14.08.16
8 Fan 14.08.16
9 Cooling circuit 19.10.17
10 Exhaust manifold  26.05.18
11 Oil breather pipes/filter
12 Differential oil 23.04.16
13 Gearbox oil
14 Engine oil
Chassis (on axle stands)
1 Adjust speed sensor
2 Panel: tunnel top 10.12.15
3 Vinyl - Tunnel top & aux panel  10.12.15
4 Fuel sender unit 22.06.16
5 Front suspension final fit & torque N/S O/S 25.02.18
6 Scuttle & Firewall final fit 
7 Fuse Box  27.11.16
8 Battery loom 27.11.16
9 Front shock absorbers 18.02.18
10 Front discs 10.03.18
11 Final Fit Battery tray  02.10.16
12 Fit Nosecone  07.07.18
13 Fit Bonnet 02.09.18
14 Headlamps 29.04.18
15 Front Indicators
16 Rear suspension final torque 23.04.16
17 Rear hub nuts torque
18 Steering rack torque
19 Lower steering column 04.03.18
20 Front brakes & lines N/S O/S 04.03.18
21 Torque suspension nuts 04.03.18
22 Fill and bleed brakes 
23 Rear wheel arches 
24 Rear lights 26.05.18
25 Boot cover
26 Dashboard  
27 Dashboard loom
28 Emerald ECU
29 Boot floor 27.11.16
30 Manifold
31 Bonnet Manifold opening 27.08.18
32 CAT & Silencer
33 Nosecone grill
34 Wing mirrors - cover the nuts, shrink wrap
35 Rearview mirror
36 Front wheel arches
37 Seats, Seat belts 27.12.16
38 Wheels & Tyres
39 Tyres, valves & balance wheels

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