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!

SFRO 2 - PASSED!

It was a border line case but it was a PASS! In the end it was a case of how much rockwool (used as house insulation) to put in the exhaust pipe without producing too much back pressure while still reducing the sound. The car went through the sound test with 84dB(A) and the limit is 84! I'm going to have to change air filter because at high revs the back pressure was slightly too much creating a sound that went well over the limit.

I get the feeling though that the MOT (registration test) will be harder as emission levels, brakes, lights etc are all checked. The ICL shows Miles as standard and kilometers in the inner ring, I hope this is acceptable.

Now I need to find an earlier date than the September 12^th that I have been offered …

Quick update

I've been away on holiday since the last SFRO test working on another building project so haven’t thought about the project in the cellar. The SFRO retest is scheduled for next Wednesday (20th) so tomorrow I'll get everything tightened that was loose and also solve the sound problem, how I do that will come later ;-)

The bad news (so far) is that once "she" gets through the SFRO test I can't get an MOT test (bilbesiktningen) until the 12th of September, it was the first free date they had. If I had known I would had booked it long ago. However there may be a chance - the Swedish besiktning was privatized recently and there are now 2 or 3 other alternatives I'm hoping will have earlier dates. I’m also able to drive the car to the test which gives me the freedom to get the test done anywhere in Sweden. Within reason!

I hope the weather holds for Wednesday …

SFRO Test Results

Pulled just about an all nighter to get the electrics fixed, dashboard in place, all the buttons connected, brakes bled which meant real wheels off for the 20^th time and to check everything still worked. 

The original instrument panel from the donor in place with expandable foam.

Instruments in place as well as buttons for lights, hazards etc.

Up again to collect the trailer at 06.30 Wednesday and Neil and had the car loaded and on the road by 07.30. 140km trip north west of Stockholm to Västerås airfield .

Unloading and I must say a  bit nervous!

The test guy had hired a small runway to do the sound test as well as generally check roadworthiness. There was also a motorcycle import from the States and a hot rod that were being tested. The rest of the checks were done outside one of the hangers, no hydraulic lift or pit which I thought was strange. In fact the whole test was not exactly what I had expected but in the end it’s required to be able to get it to the next stage, the normal Bil Besiktning (MOT).

The test guy starting one of the tests (I wasn't allowed to drive it at all!)

Now for the results: There were some small remarks for example, lose clutch pedal, lose mirror and a few other things I had neglected to tighten. All the major worries I had regarding steering, hand brake cable to calliper etc were unfounded. The one thing that it failed on was the sound, which I thought was going to be a close shave but not as bad as it turned out to be. Driving past the sound detector in 3^rd gear with the exhaust facing it produced about 92dB which is 8 over the required level. The small muffler I had bought and wrapped in wire wool was not enough especially as I had driven 4km or so with it, there was nothing left of it once it was time for the test! The thing that makes me really kick myself is the fact that after the test we were advised (not by the test guy) to fill the whole of the centre exhaust pipe with dense wire wool, the Brillo pad type, which we did once we got back home. It knocked the sound level way down and would have passed the test easily. Now it’s a retest in approx. 2 weeks and will have to hire a trailer and do the 200 mile round trip again – never mind at least everything else went through, so I’m happy J

The report mentioned that the road handling and quality was very good - which I'm really happy with. He had the wheels spinning and tyres smoking so it was a thorough test (thrashing!)

Just electrics to do

Last minute odd's and sod's done today. Finished the bonnet catches, riveting, attached the grill, checking for things not done, wing mirrors and even pulled the plastic protection paper off the panels.

Used the Dremel to cut out a larger hole for the grill. I used an M3 die to make a thread for the grill supports.

I added some rubber strip between the rear panel and frame to stop any possible vibration.

Everything in place except the instrument panel and switches

I went for a long drive today, well about 4km around the streets and it was so fantastic, it's made all the hours in the cellar, probably 300 or more, all worth it. Got to about 65km/h (very quickly) with no major issues, a few vibrations which  I'll need to find. Aluminium and black looks great but the look of the aluminium won't last and besides I'm sure an all black car will look great.

No helmet hair for me!

SFRO test worries:

• The upper steering joint - Although I think it's okay!
• The bonnet - the catches make the bonnet a little lose
• Not sure about anything else, brakes! wheel alignment ....

One day left to get ready for the test

The SFRO test was postponed to this coming Wednesday but even with an extra couple of days it's been a struggle to get everything ready. I've had a list of 20 things to do and have only tomorrow to finish ticking everything off. The upper steering bracket is now in place. I got myself a piece of 2mm steel and used the nibbler to cut it to shape. The BMW support housing fitted snuggly and hopefully it will pass the test.

The bracket had to be about 3cm longer

Bracket painted and bolted to the bulkhead, frame and BMW housing.

On Tuesday I managed to bend the bonnet almost to shape using a large industrial sheet metal bender (with some help). 

Neil came around Thursday evening and we managed to bolt in the passenger seat and rails, a very time consuming and awkward job. One of the exhaust support brackets bolts luckily came through the floor exactly where the rail was sitting so fortunately it ended up serving two purposes and was quite a neat solution. It means that both seats are adjustable and are the same height off the floor. We drilled and Cleco'd the scuttle (black dashboard) to the aluminium bulkhead.

Neil kindly finished riveting the side panels and we test fitted the bonnet. It just needs some slight adjustment of angles. Tonight I fixed the two bonnet catches at the rear and tomorrow will adjust the front and attach the catches.

The catches have to be riveted in place and there is no adjustment!

This next part is maybe something I shouldn't mention (The walls have ears!) The  sound level maybe a bit too close to the limits so the muffler insert helps reduce it.

It's not what you think it is! The muffler on it's own had no real effect as the diameter didn't match the exhaust pipe (plus it rattled). A bit of wire wool wrapped around with wire reduced it from around 80 to 72dB (Idle in the garage)

I bought an extinguisher when Fredrik and I picked up the kit in January. There wasn't much space for it in the car so I riveted it in the rear luggage area. I was also concerned about stone chips from the front wheels so bought a couple of trailer mud flaps from "Jula". They are a little too narrow but will do until I find something else.

I will need to order a new windscreen from Peter as the old one, placed high up on a shelf for the last six months came down with a crash after the bloody cat was wondering around up there!

I'll peel all the protective sheet off all the panels on Wednesday before it goes for the test.

The electrics are all done and working exept the main/dip headlights. Hopefully Peter and I can get this sorted tomorrow so I can then get the switches and instrument cluster in place.

Midsummer weekend

It was midsummer in Sweden so some drinking and good eating was done but funnily enough I still had some time for a few jobs on the car! The steering wheel is now attached with a new boss (third time lucky!) and it actually works with the horn too. In the end it was a very simple solution with a BMW spring loaded brass connector and a boss from Rally Design in the UK partnr: BM25 which has a brass ring on the inside so when the steering wheel turns the brass connector and ring are always in contact. 

The small spring loaded brass connector

Looks quite nice with everything attached

I fixed the rear number plate light above the number plate as under would have meant drilling and bolting through to where the tank is situated and it's too tight behind there. I checked out the illumination, seems okay just hope it passes the test.

This could work couldn't it?

The SFRO test has been postponed until the 6th of July but I still have to get loads done. I fixed the rear boot space. It still needs edging and perhaps a carpet but that's not required for the test.

Boot floor held in place by Cleco fasteners just in case the test guy needs to look at the fuel tank

As there were a couple of nice sunny day I fixed the front indicators. Also (with help) I managed to sort out some of the wiring so hazards, indicators, sidelights, brake lights and reversing light all work. Just a small problem with headlights, low & beam and the repeaters left. I can't fix the dashboard until all electrics are sorted out.

The grill hole is slightly off horizontal so I'll need to make some adjustments - later!

The only main mechanical job I need to finish is the upper steering bracket. Peter kindly sent me the correct BMW housing although the one I ordered from BMW was also supposed to be the correct one. All that is left is to make up a new bracket to bolt to the chassis as the one I have is a little too short.

The correct housing on the right

Bending the bonnet tomorrow ...

On the way to SFRO

I decided to book the second SFRO test for the 29th of June so it would leave me the rest of the summer to put things right as well as get it through the usual bilbesiktning (MOT) so I can at least drive it legally before the summer ends - at least that is the plan! With that in mind I got down to ticking a few things off the to-do list. I finished both rear wings and bolted on lights and number plate bracket.

Not sure how I should fix the number plate light, under, over or either side!

Then came the driver's seat with adjustable bracket. As it's quite difficult to keep the slide rails completely parallel I made a template out of wood and used that for drilling through the seat and floor pan.

Not sure what to do with the passenger side as the exhaust bracket bolts make the floor uneven. I don't intend to have it adjustable so may have to remove some of the underside of the seat where the bolt heads go.

4 point seat belt also installed. It'll be much safer when parts drop off at high speed - perhaps that comment is tempting fate!

Another quick job (thanks for the tip James) looped and riveted the fuel overflow

One job I didn't really look forward to was fixing the cycle wings. Bolted the brackets in place first (upper ball joint) and drilled and bolted the side of the bracket. I made a template out of a coat hanger to copy the angle of the wings

M8 bolt through the side

The support rods where a little far from the tyre so a metal rod bent them to the right position

I used metal bars and the metal rod to gradually bend the supports to the right angle and position

Both sides bent and drilled

Used a gradient drill to make 18mm holes for the indicator.

Repeater indicator in place, maybe a little too close to the tyre. Have to sort the cabling out next.

Then today I started on the number one job I have avoided for months, cutting a hole in the dashboard to accommodate the BMW instrument cluster  (ICL). I started by marking the recommended 40mm up from the bottom of the dash and made the first cut. Then it was a case of using the Dremel to gradually sand away small amounts, checking the ICL and repeating that fifty times or more. A good tip, have the vacuum cleaner on and next to the Dremel.

The Dremel slipped a couple of times so I'll have to touch up the fibreglass. The fibre glassing isn't the best in the world anyway so it has no be spray painted anyway.

The underside of the dash also had to be trimmed to allow the steering wheel surround to fit into it. I may have a problem with the SFRO test if they decide that the instruments are not clearly seen behind the steering wheel. Perhaps a bigger steering wheel may help (just to get through the test :-)



The ICL has to be fixed in place with foam but I'll leave that until later.

Saturday was a great day, the sun wash shining and I took a couple of tours around the streets to see how she felt. The brakes are great, the suspension needs some adjustment but generally she rolled perfectly over the bumps, gear changes felt good and the sound - the sounds was awesome!

Back to the front

A few things have been done since the great escape. I decided instead of doing jobs all over the car, I would try and concentrate on getting the rear done and then move forward to the front. Got one of the rear panels bolted on. I used a 3.2mm drill at 10cm intervals around the inside rim of the wing and the used the Cleco fasteners to keep it tight to the body. Then took out one at a time and re-drilled to the bolt size as well as inserting the rubber sealing band in between wing and body.   

Had to make sure rivet holes etc were covered by the wing as well as the wheel being central.

Once in place I bolted on the brake light/indicator cluster. Had the car horizonatal so it was straight forward to get the light straight.

Rear light cluster in place.

The cluster wiring, I think I'll put this in a rubber tube so it's a bit more robust.

Then I got the riveter out and finished off both the driver and passenger sides. If I was doing this job from the start I'd buy an air driven riveter to save back ache!

The picked up the tank bracket and bolted that in place with a strip of bike inner tube to hopefully stop any vibration (this is looking done behind the tank)

When I did the test drive last week the accelorator got stuck so I decided to redo the cable and connection to the pedal as well as trim off the connection to the manifold. I drilled up through the hole in the pedal so it would come through the bulkhead at exactly the right position instead of where I had it, which made the cable bend at the wrong angle. I got the angle grinder out and removed the top part of the cable bracket as the bonnet would have hit it.

Inset is how it was.

I also found out that the mileage and trip meters are back lit and the bulb had gone that's why I could see them before. I removed a bulb from somewhere else which wasn't needed and bobs yer uncle there it was!

The wood looks good but I don't think I'll use it in the finished car!

Freeeedoooom!

The modified steering arm arrived from Peter yesterday and Neil and I spend this morning attaching it. The upper bracket doesn't look right and I'm sure will need modifying to get it SFRO approved but the lower bracket is doing a great job.

The steering arm, plug welds in three positions around the circumference of the joints - SFRO should be happy now!

The lower bracket - room for some adjustment but probably not needed.

The upper bracket (round, black top right) with the BMW steering arm going through it but how should it be attached - Help needed! 

Once the steering was installed it was time .......

I need a lesson in how to drive!

The first trip up the road and back was a pure exhilaration. I had to hold on to a few bits and pieces as the dashboard isn't installed yet but apart from that it behaved beautifully and sounded fantastic! The response through the gears was unbelievable (only got to third)! Another quick video - listen out for the sound of something hitting metal at high speed.

I don't think it was the neighbour taking pot shots - mind you!



... then it was back to getting on with the build and trying to fix the dashboard. The gradient drill worked very well drilling out the holes for the buttons.

Looks pretty good, I'm not sure if they have to be in any particular order.

One more update photo as I'm really happy with how it's going!

Small sump leak but I think it's a bolt that's too long, a little smoke from the exhaust joint but that was just oil I used to help put it on.