The light at the end of the tunnel

After a very fruitful trip to Maidstone meeting family and friends, I came back with Christmas pressies and crackers and bits for the car; soft top, new longer wishbones, a couple of LED rear lights and a few other small odd and ends. I then had to make the painful decision to get the car up on stands and start the long list of jobs instead of taking it out for “just one more drive”

Drove down to  Burgess Hill to meet James and finally see his car. (in the picture Andy not James)

First job was to start stripping. I have kind of decided to start at the rear, concentrating on preparing and removing the panels ready for painting. I’m still not actually sure whether the rear panel will come off.

Quick check of the soft top - poppers have to be rivited on.

Bought a couple of LED lamps to replace the rectangular ones. Will sort out how to fix them later.

Enoyingly enough my MC jack packed up just as I got the car on the stands. Will have to fix it if I'm ever going to get it down again!

Fuel tank removed.

It was very difficult bending the top edges of the rear panel without getting a bumpy finish so I'll need to file the rough parts and finish off with fine sandpaper.

Hopefully once the rivets are removed from around  the base of the panel it should just be a case of lifting the panel over the frame - I hope! Just for fun I found a reversing sensor kit on ebay and started drilling holes in the base of the rear panel to house the sensors. Hopefully the fog and reverse lights won't interfere.

A 22,5mm drill is included in the kit. The holes need cleaning up with a file before the powder coating.

The rear looks very bare. I’ll try and find some smaller diameter LED lights to replace the square fog and spot lights.

Not sure how to solve this (taken off) side panel as I made a real dogs ear of  it while bending. I'll chat with the powder coat chap and see what he suggests. 

See you in 2012!

Finally succumbed to the winter!

Well it finally happened. It's not that it's too cold, more like it's a bit wet and slippery. This video was taken on Sunday 11th while there was at least some light. The weather hasn't been this mild in years which is great. Another positive point is the fact that the days start getting longer in another 10 days!

There should be snow everywhere at this time of year! There also seems to be a distinct lack of a passenger too - where are all the vikings?

There was a loud scraping sound coming from the rear passenger side and when I investigated it turned out to be the end of the handbrake cable scraping on the inside of the wheel! I'm  not totally sure what has happened but as a temporary thinking outside the box fix I put a wheel spacer on either side of the car. This brought the wheel away from the offending cable - problems solved! 

Doesn't look very nice with all the rust. I'll definitely do something about this over the winter.

The offending cable ending. I knew this wasn't right when I put it in but there hasn't been a problem until now.

The inside rim shows a little sign of wear.

I'll be going to see Peter at GKD at the weekend to sort a few things out as well as pick up my nice new soft top! May even meet up with James who is having his IVA Registration test tomorrow - good luck!

Winter draws on - not yet!

Quick update with how I've just about decided to paint "TYZee" or "TYeeZ. I found a company in Södertälje who will powder coat all the panels, the only problem is I have to get the panels off! This will require drilling out all the rivets which will mean the bodies will be left in the chassis but I can fix that by spraying in rust shield which I have been told is slightly sticky so should stop the old rivets from rattling around as well as rust protecting!

The black looks great. If I can get the wings and nose cone painted in the same colour it should look brilliant and less like a kit car!

Even though the temperature is going down it’s still okay to drive while there is sunlight, which means I can’t drive it to work as it’s dark by about 4pm. After dark it gets a bit nippy but it can’t be any worse than driving a snow scooter. Winter tyres are compulsory from the 1^st of December so I have another few weeks of opportunities.

Like everest - Wind chill is a bit extreme at 90mph!

Thanks Mikael! - Not sure about the colour, perhaps I can get a new one from photoshop!

Nice picture Mikael

After months of design and development I finally finished the soft top. I could have done with this on several occassions but it wasn't fully tested.

A little disappointing to see rust appearing on the discs. Will have to treat them with anti-rust paint. It'll be interesting to see how the rest of the car has faired ones I get it up on blocks!

Anette was pleased that I changed her car to winter tyres and was even slightly impressed that I could do it in the new garage. So was I actually but then again the Peugeot has a better turning circle so there wasn't a problem reversing it in.

Pushing the limits of mans endurance and stupidity!

I perhaps have already mentioned that a well known Swedish saying goes something like this “There is no such thing as bad weather, only bad clothing!”. After all the years I have lived here I’m finally beginning to agree. With a ski hat and goggles, gloves, scarf and nice thick jacket I have driven at +3 oC not including wind chill, which at 80km/h is probably quit high. If it’s only cold we’re talking about then I’m all for going lower but yesterday it was a test of both cold as well as rain. Kevin was over from the UK for two days and as it was he who re-planted the idea of building a kit car of course I had to take him for a spin! What happened yesterday?

Arrived home wet and cold, ready for a pizza and couple of pints!

It was the worse damn day for anything especially driving an open top car. I should have realized when I hopped in the car after work and noticed a centimeter or two of water swilling around inside (I forgot to take my trusty tarpaulin) this wasn’t going to be a good day to show off my pride and joy. But I’m a Britt abroad and nothing, but nothing was going to get in my way. It took and hour to drive from the south of Stockholm to the north through heavy traffic and heavy rain. At one point I drove through a large deep pool of water and it was like something out of the Poseidon Adventure; just as I looked up a huge wave of water flew up and over the windscreen and crashed down over everything. If I had been a small boat I would have capsized. Eventually found Kevin but the only thing we could do was to shelter at the nearest petrol station until the rain subsided.  

 He looked well happy as we drove back south again, still drizzling and with the feeling that every driver on the road must have thought we were complete idiots! But on the positive side the car performed well with not one electrical problem. Just the large hole in the roof to fix.

 

Chocks away - Like the pioneers of the past, no challenge is insurmountable!

Started to design a possible extension to the dashboard at the weekend for a clock and air temperature gauge. Cut out from cornflake packets I'll eventually cut it in aluminium sheet, solder it and then cover in black leather or similar.

May put a small lockable door on one side for small items.      

I'm going to try and keep driving the car when ever the skies are clear and the sun's shining at least until winter tyres are needed - I'll probably be alone though!

Out and about

Even though the weather is getting colder I have still managed to get out for a spin or two. Out again yesterday, temperature around 10oC. Went for a drive to the Cafe down at the lake, not exactly a motorcycle meeting place but still nice with a view across the water.

Neil - was going to have a go driving but motor cycle boots tend to spread over two or three pedals.

Then it was off down to Rosenhill again. It was good to see there were still some hardened MC riders down there, it's thinning out every week though!

A quick spin up the road but will wait until next spring for a new challenge!

Too much grit on the road

It was great on the way to work the other day but after lunch the heavens opened. Lucky I took my trusty tarpaulin with me, it didn’t look so professional but it kept the rain off!  I did notice that one has to take it very easy in wet conditions. A heavy foot and the back wheels slip very easily. The first time it happened it was a bit scary (only did it twice). Perhaps I need traction control?

Out last weekend to Rosenhill cafe, a popular motorcycle meeting place. Sunday out again along some great winding roads. The car corners very well, even Neil on his Suzuki Bandit 1250 had a problem keeping up! Actually that's true, cornering is much faster in the car but while the engine isn't tuned properly it still kept up quite well with the MC.

 

Here is Berndt Jansson one of the great Swedish rally drivers of the 50' & 60's at Rosenhill. I should have offered him a drive in the car!

On the way to Mörkö for a coffee

I

Finally street legal, best of all the sun's still shining and the roads are clear of snow!

I checked the Transport Authorities home  page several times last weekend but nothing showed up until finally Monday the car had been registered. The plates then turned up on Wednesday. I called up and sorted the "enthusiast insurance" which was very reasonable at 1800:- a year. Then "activated" the car which means I have to pay road tax. Road tax is dependent on Co2 emissions which on this car is 140 g/km which is quite low for the type and age of engine.

Took me a few minutes to attach the rear plate and off I went for my first legal spin! Drove to work Thursday and tried flooring it a few times - well I had to didn't I? The sound fits the car perfectly but it backfires which also sound pretty cool too but perhaps something I can get rid of with a good tune up. In fact between 5 and 6k revs it coughs quite badly so a tune up is definitely on the cards. Drove to Stockholm in the evening for an Indian with the lads. On the way back home the clutch stopped responding so had to struggle home in 3rd. I'll take a look tomorrow to see what's happened. Hopefully it only needs bleeding.

The mini number plate attached nicely to the underside of the nose cone with a couple of bolts. The rear slipped into the holder that I'd bolted on earlier.

To finally be out on the open road after all the uncertainties of the last two months is incredible. I was asked by James who is also building a GKD with the same engine (http://www.mylegend.im/) if I'd do it again. Simple answer; It's been such a fantastic experience I'd do the whole thing again tomorrow! Luckily enough I have loads of jobs to do on the car before the spring, like heating, windscreen wipers, carpets, soft top, storage space, a few more dials etc. etc. etc. I'm not sure how long the weather will hold but once the snow comes the jobs start. Plenty to help me escape from the Swedish winter!


UPDATE: Took a look at the clutch this morning and it was something very simple. When I first attached the clutch cylinder to the pedal the bolt had to be shortened slightly. I used and angle grinder and left the nyloc nut on as a guide for the thread. I made the mistake of reusing it as the heat had melted the nylon and it simply had come undone!

Even the bolt holding the clutch pedal to the pedal box is a bit short!

Close but not quite a cigar!

Not sure where the time is going but it's definitely not hanging around and the temperature is sinking quite quickly. But now to the good news!

I got a letter on Monday giving me details for paying in the charge for the exemption and once the payment was received probably Tuesday it took until Thursday for me to receive the exemption approval.. 

Then came the re-test which was this afternoon at my house and that was also a pass, both  the lights and seatbelts were okay! Now it’s only a case of getting registration plates. I was very much hoping that I’d at least get to know the registration number today but alas the computer system at the transport authority was down so Dekra couldn't register the paperwork. Once registered it then takes 2 or 3 working days for the plates to arrive in the post. Pity as the weather looks great for the weekend! 

It’s all going to be fixed by next weekend, I know it!

It is an amateur build - kind of!

I received a long awaited phone call from the Transport authority today. I must say I was very nervous, not knowing what to expect. First I was told that my appeal had failed,they agreed with Dekra!

BUT I was told that under the circumstances they would make an exception, sorry I mean an exemption! (one can apply for this if one can't, for various reasons comply totally with the rules - costs 1,200:- ) Once I get the letter, hopefully Monday, I can get the re-test booked and after that, registration plates and hit the road! 

What a great way to start the weekend!

No news yet!

I ordered new safety belts from CBS in Kent for around £65 including post and they are now installed. CBS or Car Builders Solutions is a great place in Staplehurst, Kent close to where I grew up. They offer any type of kit car accessories, the type of things an amateur can't make or weld themselves, like lights, seat belts, brake fluid bottles etc.

The belts were very simple to install in fact, luckily enough all the mounting points were in the right places. They don't look quite so good as the Sabelts and are not as safe but that's not such a big deal is it!  

The Sabelts were very easy to get in and out of in an emergency but now the buckles on the new belts are quite difficult to get to in such a confined space.

I took the car up to my local garage so the lights could be checked out. The mirrored test system showed they were slightly too low and slightly too far apart. The guy fixed it for me for free, (thanks Shlemon) so that is the second point crossed of the things-to-do list.

Funnily enough when both jobs were done I called DEKRA and asked them if they could book a re-test as the question of amateur build could be handled separately. I was given a blunt "NO". This is probably because they don't believe the car should pass as an amateur build so why waste their time doing a re-test! 

I'm still waiting and hoping, occasionally going for a quick spin around the block. It's a real shame as summer is nearly over and I may not fulfil the plan I had before starting the build "... so it's ready when the sun's shining and the roads are clear of snow!" 

Lights, belts, action

The appeal is now in the post and on it's way to the Transport authorities so I hope to hear some news within the next week or two.

I had another look at the headlights to check what they actually meant by failing them. Having thought they must be neutral I noticed actually that there is the tell tail larger triangle on the right of the glass and smaller to the left and so, as I understand it, are for right hand drive traffic. The glass is also marked E26 which I believe means its been approved in Slovenia and they are right hand traffic - Please comment if I'm way out cycling (a Swedish term for being wrong!)

I also checked the spread against the garage door and it definitely shows the distinctive upturn of the light to the right.

I'm not sure  how clear this is or whether it should be more distinctive. I may have it checked out before I go for the retest but as far as I can see there is nothing wrong with it. Either the lenses were dirty or fogged up in some way or the test equipment wasn't set-up correctly - that's my theory at least.

The 3 point seat belts have been ordered from Car Builders Solutions in the UK so hopefully they will arrive before the weekend so I can get them installed and crossed off the list.

Good and bad news!

First the good news!

The longest test drive the car had done up until Tuesday was about 8km around Tullinge. The drive to Gothenberg for the test was 1000 km round trip (600 miles) so to be slightly cautious we decided to take a "support vehicle" driven by Neil full of tools, spare this and spare that and also a trailer just in case of breakdown or thunderstorms.

We left the trailer about 120km from Gothenberg and drove the rest of the way together - must be skiing season!

The car performed far beyond my wildest dreams. Not one single problem during the trip down or the 300 mile trip home again so the trailer wasn't needed! I threw caution to the wind and gradually towards the end of the trip wound her up to around 90mph! Fantastic acceleration, road holding, steering, suspension, fuel consumption, in fact everything was fantastic! It even rained at one point for about 10 minutes and the rain just blew over the top with a few drops landing on the dashboard, so I know the electrics can handle a small shower. The temperature gauge stayed exactly on half the whole way, oil level was the same when I got  home as well as water level.

In the blue corner - the car weighed in at 686kg which included a 3/4 full tank and a bag of tools in the boot. So raw weight I would say is 655kg, a little heavier than I thought but at least I had no issues with it being too light. 

DEKRA is quite a new company, all the lifts and tools were squeaky clean

This is how it looks after 300 miles, I was well pleased and got some nice comments from the guys in the shop. 

Now the bad news!

Some small issues were found but nothing that had anything to do with how the car was constructed or how safe the car was, nothing that said the brakes or the steering were hazardous, I would have completely understood if it was not 100% mechanically safe and would have been only too glad to fix anything that was potentially dangerous, in fact I had done this earlier when I changed the brake pipes,  steering rod and track rod ends. I wasn’t prepared though for failing on:

• Seat belts. I had problems with this earlier so I was prepared to some extent but here is the rule. The rules in Sweden state that the belt must be a 3 point belt ie attached to the vehicle at 3 points. The 4 point belt that is common in the UK for open top, sports type vehicles and proven to be safer than 3 and e-marked throughout the EU is not allowed!
• Easy to fix with a new set of belts.
• Head Lights. The glass I have is of the type “Nuetral” which means it can be used in both left hand and right had drive vehicles. I can drive here and I can drive home to England without disturbing oncoming traffic. In Sweden this type of glass is okay for motorcycles but not for cars. Cars have to have the correct angled glass for driving on the right.
• Also easy to fix with new glass. 

Okay both these issues I can accept although they go beyond logic and I’ll fix them but the show stopper was one small paragraph in the rules VVS 2003:22 Kap 41 paragraph (http://www20.vv.se/vvfs/pdf/2003nr022.pdf) which goes like this:

Amatörbyggt fordon

Fordon som tillverkats av enskild person för eget bruk eller fordon som ändrats av enskild person för eget bruk i större omfattning än vad som avses med ombyggt for-don enligt definition ovan. Med amatörbyggt fordon avses inte fordon som från tillverkaren levereras helt eller delvis i bygg-sats och som därefter monteras ihop av enskild person för eget bruk.

The first paragraph roughly translated to:

The definition of an Amateur built vehicle is:

“Vehicles manufactured by individuals for personal use or vehicles modified by individual for personal use to a greater extent than is provided in converted vehicles as defined above” (Rebuilt vehicles).

Which is fine, completely understood. It’s for my own use, I didn’t built it for profit and I definitely, after the blood sweat and tears I have shed over the 350 or so hours won’t be going into serial production! This is where the rules should stop but there is more!

Then there is the second paragraph:

“Amateur built vehicles are not vehicles supplied in whole or in part in kit form from a manufacturer and then assembled by individuals for personal use”

I understand to some extent that they want to discourage individuals from buying complete kits as they may start pumping them out from their cellar production lines but the statement “OR IN PART” will probably kill off kit car building in Sweden. It’s basically not possible for an amateur with limited or no welding skills (like me) to build a car like this without buying some parts from professional companies who specialise in home built vehicles. So there will always be parts supplied IN PART from a manufacturer.

It's basically implying that it's better to have a car on the road that has been welded by an amateur than one that is welded professionally. Also one has to be a professional welder to build an amateur car!


I now need to appeal the decision by sending a letter to the transport authorities as well as documented evidence! I'll do that by sending a copy of this blog (maybe taking away some of the politically incorrect comments related to Swedish law J) and hope the decision is reversed.

However, once the disappointment had subsided slightly it was time for the drive home.

It was actually quite cold at speed and a little noisy from the bufferting wind. I tried ear plugs and the improvement was dramatic, a real pleasure!

At a steady 50-55 mph the fuel consumption was around 7 litres per 100km or approx. 40mpg. On the way home with the foot closer to the floor between 65 and 90mph the consumption was 36mpg or 8ltrs/100km.

I tried and empty tank test but bottled out when the needle was just about to drop out the otherside of the red so there were a few more miles in there. Distance 262  miles (422km) on 33 litres of fuel. If I had reduced speed to a steady 50-55mph I estimate a tank would last almost 300 miles (500km) which is fantastic for such a small tank (approx 35 litres).

I had to try didn't I, it's okay for a first test but I could have hung on longer in the gears and had a heavier foot!

It's a real disappointment and I'm devastated having the car fail for completely illogical reasons but I have my fingers crossed and I'm generally a positive person so I hope within the next few weeks I'll get the news I need.

I've fallen for the two tone and may keep it this way. I'll get the black fibreglass filled and painted I just need to find a way to preserve the finish of the brushed aluminium.

Registration Test looming

Well the summer has been great and I've had 5 weeks holiday! Actually that's not such a big deal in Sweden; just about everyone has at least 4 weeks off. We were down in Provénce for ten days, very hot and it would have been ideal with a softtop! It would have been a hell of a drive with our arses 10cm of the road but once down there the mountain roads are fantastic - Next year perhaps!

The registration test has been a long wait but at last the test in Gothenberg on Wednesday is the best I could get. Today I've spent going over the car checking nuts and bolts and found all the half shaft bolts loose so the check was worth doing. The copper paste seems to have warn off so the car squeeks quite badly. I tried spraying the joints with silican so I'll see how that goes. I also bit the bullet and polished the bonnet. It had been badly scuffed with the straps holding the bonnet down when on the trailer and I thought about just leaving it until it was painted. I tried on a small area with wire wool and metal polish and the result was great. 

This is one side wire wooled along the grain, well at least the metals natural finish. I put on some polish and the used the wire wool all over to gently to remove the scratches. Another coat of polish on a cloth and then polished like hell to get a good shine - it was worth it though, the finish is great and I may even leave the black silver finish of the car but I have to do the sides and boot too so that may change my mind.

This is one side of the bonnet done. It's hard work as the metal goes black and it takes a lot of clothes to get it to a even shine.

Up on blocks checking for anything loose! I also moved the dashboard mirror and got rid of the mirror stuck to the glass as it was useless, vibrated badly and also kept falling off!

Neil and I intend to leave Stockholm on Tuesday at 7pm and drive the 500km to the test centre in Gothenberg for the 10.00am test Wednesday. We'll be taking tools, spare nuts and bolts, water, fuel, brake fluid, sleeping bags, skiing goggles, hats and a great deal of hope - "hope is a good thing maybe the best of things. and no good thing ever dies" (Andy Dufresne)

Lets hope the car doesn't!

MOT moving closer

Ready for the MOT - I hope!

I ring the MOT organisation everyday to see if anyone has cancelled their test. It just so happens that I was in luck and its been moved forward to the 30th of August. I have another one booked with another company for the 17th of August but that is way down in Gothenberg, which is a bit risky for a first time drive of 1100km round trip but risks are sometimes worth taking - aren't they? Of course I'm still ringing Bilprovningen everyday for an earlier date than the 30th which will be much closer to home. I have now sorted out special insurance to get me to the test and back as well as a bag full of tools, spare fuel, water, oil etc just in case I get a test with short notice.

Nearly done but there are some small gaps which could let rain through. I'll try and fill them with sealant

I finished off the windscreen after a great deal of messing about. It required a lot of drilling and tapping and bending. It's okay but I'd like to do the whole thing again over the winter time and make sure this time that I do everything correctly. It'll mean a new frame and probably new glass cut to the exact shape. Sweden is not exactly renound for it's rain free summer days so it's worth making an extra effort.

This is before I used a blade to cut off the extra rubber surrounding the glass. I had to remove the dash mirror as it hit the glass - think ahead! Instead I put a stick-on one on the glass but it's hopeless as it vibrates badly. I'll move the dashboard one and use that instead.

Some things to finish while waiting for the MOT

As I'm not sure when I'll get the MOT I decided to fix a couple of things. One of them was making up a bracket to hold the air filter. I bought another air filter becuase of the back pressure; haven't tested it out yet but put it in place all the same. The bracket was to hold it in place and keep it away from the manifold.

Made up a cardboard template first and then cut and filed a 1mm sheet of aluminium to the same shape.

I bolted one end to the manifold and the other to the MAF  (Mass airflow sensor) the black tube attached to  the air filter. It's keeping the air filter away from the manifold as well as keeping all the pipes rigid.

The next job, which I thought would be easier than it has been (so far) required some help from GKD as the manual doesn't mention how to do it. The first job was to push the thin rubber band into the u-shape top part of the frame.  Then the glass was put in place, as the sides of  the frame kept springing apart I drilled some temporary holes at the end and dragged them together with wire. The lower frame placed and marked where it needed to be cut.

I tried Duck tape to hold the frame and glass but it didn't work so well.

The windscreen side brackets were next, one either side of the car (funnily enough). To pass the test I obviously had to have the mirrors in place so I purposely drilled holes for the mirrors which are now used for the brackets. Once the brackets and windscreen are installed I'll put the mirrors back in the same holes.  

Bracket holes are 65mm up from the body panel and as far forward as possible.

Bolting the lower frame to the upper was a real pain. Holes had to be drilled at the right angle first and then tapped to M4. The heads of the bolts had to angle grinded to a countersunk shape as well as counter sinking the holes, oh and cut to the right length too! Then put the glass in for a test fitting. Bent the side brackets at the top of the triangle a little too much so now I need to bend them back. I also have to remove more of the side frame as it should be flush with the lower frame. 

Glass removed until everything is correctly bent and cut. Mirror using the bracket!

The windscreen in place but not finally fixed as there's the bending and cutting to do! I also have a clutch pedal bolt to swap to a longer one too. I had two to fix after the test but only remembered to do one.

Looks okay with the windscreen but kind a' liked it better without but not very practical!