Johns Zero

2009-04-19T10:10:00.000-07:00

whilst building a boundary wall my porch "fell off" only thing holding it to the house were the screws through the double glazing. Here is the micro crusher that ate the old porch.

Several time the zero nearly ended up in it!

2009-04-19T10:03:00.000-07:00

Engine in new alternator bracket made (rascal alternator) cylinder head skimmed and Fr32 cam fitted with adjustable pulley fitted. The o/s suspension removed, side panel fitted then refitted o/s suspension.

2009-04-19T09:59:00.000-07:00

Home made engine lift bracket!

2009-04-19T09:56:00.000-07:00

Once the sump was shortened the block could be lifted in.

2009-04-19T09:53:00.000-07:00

Rear end with petrol tank

2009-04-19T09:50:00.000-07:00

My financial adviser having a Brum Brum

2009-04-19T09:40:00.000-07:00

Here we have my first official

Brum brum moment

2008-11-16T10:32:00.000-08:00

The seat back panel requires trimming down to fit, clamp in place, mark the rear side of the panel where the box section meets it, on the centre line of box section mark out then drill, refit panel clamp and drill box section using panel as template, remove, bond box section refit panel and rivet in place. Seal rear of panel to box section. I have decided to use black rivets throughout the build.

2008-11-16T10:24:00.000-08:00

Due to problems aligning rear suspension I decided to fit front suspension before the side panels. This means it will have to come off for the side panels to be fitted. Front hubs were sand blasted and new bearings fitted.

2008-11-16T10:14:00.000-08:00

o/s/r suspension all wishbone bushes have to be pressed in with metal inserts. New driveshafts and a rear disc conversion. Rear hub carriers were sand blasted and new wheel bearings fitted

2008-11-16T10:09:00.000-08:00

The gearbox mount was ground out of the old crossmember,trimmed to fit and four holes drilled and bolted into place

2008-11-16T09:59:00.000-08:00

Just below petrol pipe is a thick walled stainless tube used as a spacer.the diff sits off centre so n/s and o/s require different size spacers,one is also required at the rear upper mount

2008-11-16T09:52:00.000-08:00

Front mounting for the diff. These go in first loose then the long lower bolt then the long top bolt then the upper rear bolt, at least one set of holes require elongating

2008-11-16T09:48:00.000-08:00

Rear brake T piece, petrol pipe to the left wiring loom to the right

2008-11-16T09:44:00.000-08:00

Here a panel was made to the rear of the diff to mount the motorbike fuel pump and pump pre-filter

2008-11-16T09:35:00.000-08:00

View of transmission tunnel showing wiring loom and brake line.The handbrake mounts on two plates between the two top transmission rails,these were at the wrong angle,I cut the mounting brackets on the lever,bent to shape and rewelded before fitting

2008-11-16T09:19:00.000-08:00

New master cylinder in place. I choose to use torx button headed self tappers to secure brake and fuel lines.

2008-11-16T09:15:00.000-08:00

Using the old brake master cylinder to position the brake pipes

2008-11-16T09:11:00.000-08:00

Looking towards front at fuel line note n/s/f

brake pipe in top corner

2008-11-16T09:07:00.000-08:00

Next job is to run fuel and brake lines along with the wiring loom

2008-11-15T12:58:00.000-08:00

At this stage all power has been supplied by a generator i.e. compressor, drill, grinder. As of 20/10/08 the electrity man gave me some of his power!

2008-11-15T12:37:00.000-08:00

Rear suspension wishbones, two coats rust proofer, two coats, grey primer, two coats smoothrite.

2008-11-15T12:33:00.000-08:00

I tried to claim rolling chassis status at this stage!

2008-11-15T12:30:00.000-08:00

Right way up waiting for top coat.

2008-11-15T12:26:00.000-08:00

The chassis is upside down having been sprayed in top coat, the floor pan has had two coats of underseal.

2008-11-15T12:20:00.000-08:00

As the paint system was applied by hand, at this stage the chassis was flatted down prior to being sprayed in Kawasaki green.

2008-11-15T12:17:00.000-08:00

Here is the chassis after two coats of grey metal primer

2008-11-15T12:05:00.000-08:00

The chassis has had the welds ground down flush and the metal cleaned back to bright steel, it then received two coats of rust proofer.

2008-11-15T11:41:00.000-08:00

Hi my name is John and I am building a Great British Sportcars Zero, I plan to photograph stages of the build so people can see what is involed in building a kit car.
I purchased the kit on 10/05/08 and also a donor kit which consists of engine (2 litre pinto), gearbox (Ford type 9), drive shafts, front hubs.
I plan to spray the chassis in Kawasaki green in keeping with the nose cone, front mudgards and outer section of the rear wings.
As the build progresses I will post pictures and a brief outline of the work that has been completed.