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Author: Subject: Rosco's haynes Build
Rosco86

posted on 17/12/15 at 08:00 PM Reply With Quote
quote:
Originally posted by ste
Rosco, this is a lovely build, one of the best I've seen by far.

One little thing for you though, you need to have the horns pointing down or level so they don't fill with water. Just fitted mine this week and the pack had that warning on.

Do you take orders on the engraved chassis numbers?

ste


Cheers mate! Yeah I will spin them round cheers!

Not on the numbers I'm afraid but I did see someone on eBay offering some stamped ones that look good and only about £7 or so





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Rosco86

posted on 17/12/15 at 08:34 PM Reply With Quote
Right, update time! It's been a while as I've had some issues with my bodywork from Equinox, it's took the shine of the whole project really.

To cut a long story short, hired a van, drove 3hrs, collected the panels, got home and unwrapped everything, almost every pannel had scratches on some worse than others, a few had light streaks in the gel coat, the nose cone had some good blobs of resin on the seam edge where it meets the bonnet

Rang and spoke to Dave and he explained if I wet and dried then polished, I would get the scratches out and I could work on the seam line like this to

He offered to replace any panels I wasn't happy with if I returned them but it cost me the best part of £150 to collect them the first time, in my opinion i should of never been told they were ready to collect

In the end I posted the wheel arches back as these were the worst bits and he refunded me for these, I'm going to get some carbon ones now I think

As for the light streaks and scratches I'm just going to have to try and wet and dry them out, ide rather not have to do this, but hey ho

Overall I was just disappointed as they weren't cheap and he's regarded as the best place to get the panels,

Right anyway, my colour scheme might start to become a bit clearer









Marking out for the first cut, eek!





Marking for wishbones









Air filter hole was a bit tricky but turned out sweet, might make a scoop to cover it at some point



Ordered some tyres and wing stays from Mk, in stock and turned up next day, I wish all suppliers could manage this





Also got my rims





Longer wheel studs and new nuts



First fit of rear wheels, all clears nice etc



I made a handbrake surround, just got to make the cloth bit





That's about it, I've been on with other little bits but that's about it, it's been a bit slow going this last month but I'm trying to get cracking but the body works a two man job really so can't do much in the week

As for the body panels some might think I'm being fussy but I just expected them to be better





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rdodger

posted on 17/12/15 at 09:07 PM Reply With Quote
Inspired choice of colour.

Not something I would have considered but looks to work really well!






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Rosco86

posted on 17/12/15 at 09:35 PM Reply With Quote
quote:
Originally posted by rdodger
Inspired choice of colour.

Not something I would have considered but looks to work really well!


cheers, yeah took me a while to decide to go for it!





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Adamirish

posted on 18/12/15 at 12:04 AM Reply With Quote
Great update and for the record, I wouldn't have been happy about the bodywork either. IMO it's just not acceptable. Surely they should be supplied ready to just cut and fit. The scratches could ruin one of the best builds I have seen so I do hope you can flat them out mate.

Good to see that the air filter isn't as obtrusive as I first thought it may be. Great work!





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CosKev3

posted on 18/12/15 at 08:22 AM Reply With Quote
Gutted for you about the bodywork,as above its sold as a finished product it should not need any prep or repairs.

Colour scheme looks good,only downside imo to dark coloured/camouflaged seven type cars is you will blend into the background/scenery pretty easily and will need to be extra vigilant to people pulling out in front of you etc at junctions.

Bright coloured seven type cars ftw!

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Rosco86

posted on 18/12/15 at 10:50 AM Reply With Quote
cheers guys, yeah its propper pissed me off, but not really got any other options apart from a 6hr round trip etc

yeah thats my only worry with a dark colour but im not a bright colour kind of guy





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Rosco86

posted on 20/12/15 at 08:17 PM Reply With Quote
Well me and my dad have had two full days on the car again this weekend, got the side panels finish trimmed, painted the inside black and bonded on with tiger seal

Also got the bonnet trimmed to match the scuttle and the scuttle fixed on with Rivnuts









Rear tub fitted





Then made a card template for a exhaust heat shield



Then drawn up on the pic, we had to rotate so it would fit on my dads cnc



Finished product in aluminium, I might still cover this in heat reflective foil, then it will be rivited on I think







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40inches

posted on 21/12/15 at 08:57 AM Reply With Quote
This is a nice build
Regarding the wing stays, you might want to replace the flat section with tubing, it isn't rare for them to shear at the flat/tube joint.
Description
Description

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Rosco86

posted on 1/1/16 at 06:42 PM Reply With Quote
Cheers, I will have a look when I get my arches





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Rosco86

posted on 1/1/16 at 07:05 PM Reply With Quote
Right I've had three full days on the car this Christmas, and hopefully two more still to go,


Santa brought me a gopro





Space heat foil stuck on the aluminium heat shield and bolted on



Exhaust manifold fitted, and even if I say so myself I couldn't stop smiling after getting this all fitted up







Next job Dashboard, I've been struggling with this, deciding which way to go, I didn't like the look of the equinox one, I wanted a carbon one but there's not one with an iva edge,

In the end I decided to make one with deboned sheet, easy to work with etc, as for the lower edge I'm using black pvc waste pipe, sounds crude but it's turned out sweet

Template first, I used 2mm coriguated plastic from wickes, was only £4 for an 8x4 sheet and can be easily cut





Fixing holes drilled and rivnuts fitted in scuttle



Rubber grommet and sleeve for steering column



I was in the zone and forgot to take any pictures, I cut all the switch and dash holes out on my dads cnc

Back of the dash



All fitted up for good hopefully, lower edge pipe trim fitted



Full photo



Battery fitted and passenger footrest, I might block the battery off from the footwell with a bit of dibond



And a full shot for a change, starting to look like a car







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Rosco86

posted on 2/1/16 at 03:11 PM Reply With Quote
Got a bit more done today,

Boot lid temple made up



And then as if like magic



Sorry forgot to take any pics, but yes I did it on my dads cnc, still needs a bit of fitting but waiting on some rubber bobbins now
Each of the three pieces will be bolted in place with the centre easy to unbolt and remove



[Edited on 2/1/16 by Rosco86]





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Rosco86

posted on 3/1/16 at 08:41 PM Reply With Quote
Quick update from today, me and my dad fitted the bonnet aerocatches, went rather smoothly, I thought it was going to be tricky but turned out sweet







Next weeks job is to try and remember what's going on here







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Rosco86

posted on 23/1/16 at 08:09 PM Reply With Quote
Bit of an update, I've been flat out with every bit of spare time trying to get this thing somewhere near finished

I drew this up and made one, it's so I can use the bike fuel filler cap so the keys the same for the ignition and the tank



It was quite tricky to draw it up but turned out great





Started on an oil catch tank from an alu water bottle



Got some logos made up for my centre caps



Couple of bonnet location pins made



Got some front arches from MK, there proper smart, well happy with the quality of them



Decided to get some tube bent as the flat bar looked a bit naff



I used m5 rubber well nuts in the tubes to bolt them on, took me all day and stressed me out trying to get them right! Turned out ok in the end



I've not mounted them to close to the tyre as I want to be able to swap wheels early



Made some name plates for under my switches etc, there getting anodised then I will engrave them up



The next job took me almost two full days! The bulkhead, took a shot to prove I don't use cnc for everything





I've done it in two parts so I can get behind the dash easily



Inspection holes cut out



Left cover



Both covers in place



Bit of bead rolling



Everything's going to get powder coated black

Also got my brakes all bled! Pedal feels great and no leaks so I'm well happy with that

Next job is to get that wiring sorted that I've been putting off





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MsD

posted on 23/1/16 at 09:33 PM Reply With Quote
Brilliant, thanks for keeping the thread updated!
Work looks top quality. Have you started IVA applications yet?
Do you have any pictures of the harness mounts you were talking about in the other thread?
Thanks, Mark.

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Rosco86

posted on 23/1/16 at 10:14 PM Reply With Quote
quote:
Originally posted by MsD
Brilliant, thanks for keeping the thread updated!
Work looks top quality. Have you started IVA applications yet?
Do you have any pictures of the harness mounts you were talking about in the other thread?
Thanks, Mark.


Cheers pal, not started my iva yet, want to get it all finished and mapped etc I think

Hers some pics mate

quote:
Originally posted by Rosco86
This weeks progress

I started working out where my lower harness mounts were going according to the msa blue book



I've changed the book design a little, tacked in





Centre two



Upper seat brackets done, I no the top edge doesn't need a radius behind the seat, but it looks neater I think




[Edited on 12/4/15 by Rosco86]






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Rosco86

posted on 24/1/16 at 07:06 PM Reply With Quote
Was on my lathe at 6am today

Turned this up to fit the drinks bottle, bit of screw cutting to



Filter pressed on top



Then on my dads cnc for a few brackets



Bracket bent and tank in place



Bracket two





There was a threaded boss on the cam cover that I've bolted to



Then started to get the wiring tidied up and fastened in place







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Rosco86

posted on 24/1/16 at 07:08 PM Reply With Quote
Was on my lathe at 6am today

Turned this up to fit the drinks bottle, bit of screw cutting to



Filter pressed on top



Then on my dads cnc for a few brackets



Bracket bent and tank in place



Bracket two





There was a threaded boss on the cam cover that I've bolted to



Then started to get the wiring tidied up and fastened in place



That's the engine bay about finished I think







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JSG89

posted on 24/1/16 at 07:28 PM Reply With Quote
Purely Amazing.

From someone who has just started this is my inspiration!!

Great work as always!

Would love to see this in the flesh one day.

Keep up the great work.

Josh

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DRM Black7

posted on 24/1/16 at 08:27 PM Reply With Quote
Just mind blowing the little details!!! Superb mate superb
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Rosco86

posted on 27/1/16 at 09:05 PM Reply With Quote
Cheers guys, can't wait to get it finished!





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Rosco86

posted on 30/1/16 at 08:12 PM Reply With Quote
Got all my tunnel panels back from powder coating and got them fitted



Edge beading worked out perfect

Also got a load of bolts powder coated black



Oh and I've had some stickers made up saying "Warhawk" which is what I've decided to name the beast





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Digimon

posted on 22/2/16 at 04:50 PM Reply With Quote
How you getting on with the car Ross?
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Rosco86

posted on 7/3/16 at 07:00 PM Reply With Quote
Hi guys, been a while since my last update, we've had a baby girl a couple of weeks ago, hence the month off the car! I did get a few bits and bobs done before and just started getting a few bits done this week, but I think the days are long gone of spending 20-30 hours a week in the garage!

My dad made me a shelf to take my IKEA tubs



Dash label plates anodised and ready to engrave



Engraved



Headlights wired



Tapered sleeves made for track rods



Just need anodizing



Fuel filler adapter anodised





Fog and reverse light plinths made













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Adamirish

posted on 7/3/16 at 07:16 PM Reply With Quote
Congratulations on the new arrival!





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