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What is the 2B
[Or, dietary tips for Sierras]

The Build Diary
['99 - Aug. '00]
[ Aug - Nov. '00]
[December '00]
[Early Jan '01]
[January '01]
[February '01]
[March '01]
[April '01]
[May '01]
[June '01]
[July '01]

The SVA
[Did my 2B pass?]

On The Road
[Whats it like then?]
[And now it's been improved!]

New for 2003
[Suspension Mods]

New for 2002
[Engine Mods]
[Fuel Filler]
[Custom Instuments]
[Rear Shocks]

Tricks & Tips
[including do as I say, not as I did!]

Major Problems
[Or how to talk to the Manufacturer]

So you think you've got problems?

Gallery
[Or,some necessary light relief!]

Wifes View
[Or, are you coming out of that garage....]

Links
[Other maniacs who have tried this]

About the Authors
[If you are really bored...]

The Build Diary... DC - During Car
How?

The Mansfield Experience - August 19th 2000
Collected Ian, it was raining (insert suitable tirade against British weather here...). Contrary to previous comments, White Van Man was not in evidence (! - Ian). I do not have a) Poor Forward Vision, b) No Road Sense c) A Mobile Phone, or d) An un-natural interest in roadside suspended horticulture (Do I Dave?). Headed off into the rain towards Mansfield. The surface water was obviously affecting performance of the vehicle as it would only do about 55 Mph. Arrived about 1pm, expecting that most people would have already collected their kits and gone home. Joined the end of a long queue of confused looking people surrounded by a variety of vans, trailers, etc. Our turn arrived and having finally got the van into Robin Hoods yard, pushed our laden trolley to it. Then came an hour or so's 'amusement' checking off parts against the list. Other people were enjoying this underrated activity and we used a considerable quantity of shoe leather wandering between groups to see if anyone else had identified the bit of 25mm plastic drainpipe as Cockpit edge trim or the 6" coil of steel which no one had identified at time of leaving (we didn't have one of these, but seemed to have everything we were supposed to). As a matter of interest, the group next to us, had a long wheel-base Transit, and were tying the doors shut over the protruding Chassis as we left.

Down the road was a Fish and Chip shop, proclaiming itself to have 'THE BEST FISH AND CHIPS IN MANSFIELD'. Obviously, with that sort of accreditation, we could not resist! Much to our surprise, they were (Note, If I am ever to return to Mansfield, I will of course try another Chip shop just to make sure...). Suitably refreshed we headed off back to Norwich. Conversation topics plumbed new depths as we all desperatly tried to find new and interesting things to say. 'Look!' I said, 'Aren't those lovely hanging baskets...'. 'Yes' said Ian, and so on...

Back at Norwich we unloaded the van and had a nice hot cup of tea. Suddenly, the world was right again and we sat down for a quick look at the 'Build Video'. Directed by Steven Spielburg, Starring 'Sir John Gielgud', Graphics by ILM. Not exactly, but the video does give a general idea of how to build a car, although in a rather strange order (plus, you learn new methods of moving your pet dog). Handy tips abound, such as 'plug your angle grinder in before use' and 'Switch off Video Camera when things are not going together as planned'.

September 2000
Painted Chassis, as I am sick of using Smooth Hammerite for everything, I decided to try something different, a product called Nippon Metal Paint. It was different, but as it dried apparently on contact, it was quite difficult to lose the brush marks. It did however cover up the lead oxide primer which I had applied. It seems to have gone very hard, but chips easily so I'd recommend Smooth Hammerite for anyone else.

Fitted floor (lots of self-tapping screws) and fitted rear sub-frame (the Sierra torque tube and it's associated parts). It was about at this point that my Capri died so decided to hire engine hoist and remove engine from that at same time as putting engine and gearbox into the kit. With the propshaft fitted it began to look a bit like a Car.

October 2000
Decided to fit all internal panels now and leave the outer bodywork till last to avoid damaging it. As this is all stainless steel I used cobalt drill bits as they don't blunt anything like as fast as HSS ones do. The panels aren't a bad fit but do need some modification to go together nicely. They are all fixed with screws for now, but these will be replaced with rivits or nuts and bolts as appropriate later.

November 2000
Came to start front suspension. Stripped down McPherson struts from Sierra and removed collar from the chrome shaft. RHE recommend drilling out the spot welds that hold this on, but it is easier to file them off as done carefully, this does not damage the shaft. When offering up the shafts on the car I discovered that the two mounting plates that locate it were not at the same angle and thus incapable of holding it securly. This seems to be a manufactuing fault and requires quite major work to rectify as you cannot simply bend them into line.

The rear coil over shocks were dismantled to fit the new spring that RHE sent out as the original ones were bouncier than a castle. Once fitted the bump stop no longer did (cut the thick end off and use as lower bump stop for front suspension) nor did the dust cover which currently resides on a shelf in the garage. These units bolt into the rollbar at the top and the Sierra spring pans on the trailing arm. The hole in these is approx. 1 inch dia. and the bolt RHE supply is 12mm so I recommend finding a suitable washer to sandwich in the middle to stiffen it all up. (As part of the 'Learn how to build a car by watching a friend do it' program, I discovered that it is not wise to let go of a still spinning drill whilst the bit is in the hole, IF you want to have drill-bits which are not snapped in two! - Ian)

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