With the engine loom in place I wanted get the tops worked out for the transmission tunnel so that I could make up the centre console for the fire extinguisher release, master cut out switch and other additional switches I was going to need. In the end I went for:

I got the extruded alloy from The Complete Automobilist in North Walsham in Norfolk. It is a perfect shape to hopefully keep the IVA examiner happy and provide a strong fixing for both parts of the tunnel cover. At this point I am not sure how the gear lever gaiter is going to stay in place but I will work that out later!.

With my Rivnut tool working over time and a box of M5 cap head screws we start to look like this:

With this all out of the way I moved onto the centre console. In my head I wanted a large area to be able to mount the cut off switch. This was going need some thought as there would be some very robust wire involved and routing would be critical. So, armed with a Cornflake box......

I am really pleased with the outcome. The observant will see that I have laid the GKD wiring harness in place to continue the development of the overall wiring fit out. However this will have to wait whilst I fit the rear alloy panel and the car goes of to Tube Engineering for the exhaust build.

It helps if you actually publish the post rather than leave it as a draft! So, following on from my last post I have continued with the wiring. This is one area I have really been looking forward to. its probably my favourite subject.

As I said previously I wanted to make the loom once if possible so a few nights have been spent drawing out all the additional circuits, removing unwanted wiring and planning the physical fit.

I started with the engine loom. This needed physically mounting so I came up with:

I plan to move the diagnostic socket to the boot area (this will make sense in time!) so those wires will go. The starter lead will also move so the under bonnet area should look pretty tidy.

I continue to feel very enthusiastic about my build. I did wonder if I might start to lose interest over time but I have not. Its been a long time since I have wielded a spanner in anger so find myself really enjoying myself.

With the bulkhead in place I decided to complete the installation of the fire extinguisher system. This came from Sparco complete with all the fittings including two tightly coiled aluminum pipes. 

The fitting of the bottle was easy enough, 8 x M6 bolts and it was done. It fits nicely in front of the newly arrived seats. I am unsure how the IVA examiner is going to view all this but if necessary I can take it out for the examination day.

With regard to the seats, I got them from JC Composites. I dealt with Jordan who was very helpful and did what he said he would do and delivered on the day he said. Much impressed and pleased with the seats.

Anyway, I am pleased with my plumbing. I just have the rest of the engine bay to fit once I have the air intake sorted..

I have also started the wiring ahead of the new loom arriving. I have tried to think ahead of all the electrical kit I need on the car so that I can hopefully make up the loom and not have to adding the parts I had forgotten.

Its a little warmer now the snow has gone so garage time has increased! Next task was to sort out how the bulkhead and scuttle all fitted together. I wanted the scuttle to be quickly removable so that I could access where the bulk of the electrics and electronics would be located.

I battled for a long while with G clamps and tape measure until I was (almost) happy with the fit. The scuttle is not a perfect fit being too wide at the back but its acceptable. I the drilled some pilot holes for the  scuttle and then drilled them out to take M6 bolts. I made up spacers to go in the top chassis rail to prevent crushing the tube. Once this was done I assembled everything and drilled out alternate holes to take M6 screws through into the scuttle. The scuttle was then drilled out to take rivnuts. With this all bolted down I drilled all the 3.2mm holes for the rivets. And finally with a small bead of Sikaflex rivetted the bulkhead onto the chassis. I am really pleased with this now its done. It fits well and is very rigid.

Having looked at everybody else's builds I have stolen a common thread and made a additional bulkhead to support the relays etc.

I am going to complete the two covers for the transmission tunnel next.

A bit of a slow period due to the cold weather! My garage is pretty good but its just so cold even with the heater doing its best. Anyway, I have not made any significant progress it seems to be all little bits completed. The biggest of which was the handbrake cables. These came directly from the donor and were strangely new. However, I could see how the calliper end fitted but not how they were to fit into the two tubes on the chassis. My solution was to turn up two adaptors. I also used the opportunity to use the length of the adaptor to maximise the range of adjustment to the maximum.. Overall I am pleased with these.

I made up two foam buffers to stop the cables banging on the diff and diff cover (when made and fitted!!).

So, only a short update this time. Hopefully in the next couple of weeks I should be able to make progress with the exhaust system, some seats and the fuel tank.  

Happy New Year everybody. With all the festive celebrations, family visits and other jobs out of the way I have been able to crack on with getting the interior panels in place. I have enjoyed all of these tasks as everything fits and the end result is very pleasing. 

I completed all the panels for the transmission tunnel before moving on to the two main exterior ones.

Sitting in the car making brumming noise got my head round to seats. Any seat would need to be narrow and browsing the internet turned up a few ideas. A call to Peter at GKD also helped me with what was needed. Anyway, I will let this filter through the brain before ordering anything (a bit like the fuel tank, I still have not made up my mind....).
I am going to leave the tops of the transmission tunnel until later as I going to build a centre console for the fire extinguisher and electrical cut out switches.

This got me to the two main exterior panels and a colour scheme..... I am going to follow others with a vinyl wrap instead of paint so a decision was required. In the end I went for white. Ambitious I realise but there was a precedent:

This was my last tarmac Escort. Anyway, to fit the side panels the cage had to go. With little space there was only one option. I rigged up a couple of anchors in the roof and hoisted it up out of the way. I was concerned that the front legs would damage the wrap and or panel when I was moving into position so I rigged up an expansion tool from an hinge and couple of bits of wood. The really helped as I had the cage up and down for drilling holes etc

Again, I think there has been a design change and the panels have not been modified. The picture below shows the strip I had to cut off and re drill to get the front edge to fit correctly for an effective joint and sealing.

With the fit corrected I had to wrap both sides of the panel and cut away for the Sikaflex adhesive.

With all the panels on I can now get the cage lowered and bolted into place.

With the basic engine location sorted I moved onto the alloy panelling for the tunnel and outside cockpit. 
I ordered a couple of high quality Bosch 3.2mm drill bits in readiness. 

I had expected the panels to need a fair bit of trimming to fit but have been very pleased that they all fitted pretty much as they were delivered except one. I think there must have been a design change to the tunnel at the front passengers side (RHD Car) as I couldn't get it to fit.

In the end I used a G clamp to pull it into shape and the drilled the holes. With a bit of sealer all should be well.

























One of the decisions I made when the engine was fitted was to make a small removable panel so that I could get to the clutch slave cylinder for servicing. So before riveting in the panel I cut out an opening and made a suitable cover. 

On the picture below you can just see the rubber gasket I made from Sikaflex to seal the removable panel.

You will also see that I am going to cover all the interior panels with Carbon Fibre effect vinyl. I am pleased with how good this looks and with the rivets in place it has a very pleasing effect.

One I was happy with the fit and all the holes be burred I cleaned all the mating surfaces with Acetone and put a bead of Sikaflex on the chassis and then with many Clecos riveted the panels in place. 

That's two weeks work! I will add some more photos of the interior in my next post.