I need to check it over and that will take at least a working week, which will probably be several real months.
There are several things that I know it needs...
1. Bonnet rams and securing clips
- rams ordered 24/10/2022 - collected 28/10/2022, Starlock washers ordered 25/10/2022 - arrived 29/10/2022 - welded plates and secured ram pins in "lower" position... the rear of the bonnet was pushed up out of alignment... we are investigating an new pin position 12/02/2023 - spare hinge acquired and geometry measured 17/02/2023 - new bonnet lock bought 17/02/2023 - lower ball pin repositioned 13/03/2023 - strut pistons cut to length 14/03/2023 - rams fitted (but not powerful enough) 14/03/2023 - stronger rams may break the hinge - stainless steel rod and sherical bearing ordered to act as bonnet stay 15/03/2023 - threaded stainless steel rod 18/03/2023 - machined aluminium block to accept sherical bearing - bent stainless steel bar and fitted to bearing - glued block and bar to bonnet using epoxy resin - glued and pinned bar retaining clip to aluminium block 23/03/2023 - made the retaining block for the bonnet stay 29/03/2023 - retaining block attached to car, stay cut to length, stay button added to end of stay - DONE
1a. Design and manufacture ram extensions
- machined 31/10/2022 - hardened and tempered 04/11/2022 - shorter ram extensions machined, hardened and tempered 19/02/2023 DONE
2. Spinners for the wheel centres (to make them look like Dunlops)
- bought 25/10/2022 - arrived 29/10/2022 - started to look at possible solutions 21/03/2023 - cut out adapters - made mandrel for front wheel - fitted front adapter to spacer - ordered 25mm aluminium bar 22/03/2023 - finished RHF spinner solution 27/03/2023 - finished LHF and RHR spinner solutions 28/03/2023 - finished LHR spinner solution 29/03/2023 - DONE
3. Battery drain issue (probably something to do with the centre console)
- traced the drain to the clock 24/01/2023 - parts to make voltage cut-off module ordered 28/01/2023- made circuit on breadboard (less NPN transistor) 01/02/2023 - made a circuit on the breadboard that works 04/02/2023 - made the circuit board 05/02/2023 - circuit board works with variable power supply, but not with battery 06/02/2023 - tested using DC battery and resistors adjusted to suit 07/02/2023 - circuit board designed and made (see video) 09/02/2023 - started to seal the circuit board with glass fibre resin 15/02/2023 - sealed with epoxy resin 16/02/2023 - plugs added to wire ends and module / clock put on test 20/02/2023 - test passed 21/02/2023 - clock connected to car 22/02/2023 - DONE
4. Sort out the height of the car (adjustable coilovers)
- measured height of M roadster (490 / 55) 04/04/2023 - started to set the ride heights 06/04/2023 - done the best that I can 07/04/2023 - DONE
5. Full service
- started valve shims (9 out of 16 needed adjustment) - still need 2x 2.85 shims to complete the job 31/01/2023 - shims arrived 04/02/2023 - all valve shim gaps measured and adjusted 07/02/2023 - 3x heli-coils machined into intermediate head 10/02/2023 - spark plugs changed 11/02/2023 - oil and filter changed 16/04/2023 - DONE
6. Radio buttons
- bought 24/10/2022 - fitted 25/10/2022 - DONE
7. Properly clean the car of all the dust from painting
8. Wheel arch covers
- ABS sheet ordered 14/12/2022 - wheel arches fitted 15/12/2022 - "cat's whiskers" ordered 30/12/2022 - "cat's whiskers" arrived 05/01/2023 - ordered securing clips for "cat's whiskers" 09/02/2023 - securing clips arrived 10/02/2023 - fabricated arch liners to allow arches to be removed 12/02/2023 - completed RHF wheel arch liner 01/04/2023 - completed LHF wheel arch liner 03/04/2023 - secured cat whisker clips to bonnet using JB Weld 03/04/2023 - cat whiskers trimmed and wheel arch liners completed 04/04/2023 - DONE
9. Clean boot carpets and boot interior
- cleaned 27/10/2022 - DONE
10. Check wheels (I like the rears, but the fronts looks too small)
- I think this has been sorted by adjusting the ride height 07/04/2023 - DONE
11. Interior mirror
- bought 24/10/2022 - arrived 27/10/2022 - mirror to be fitted to upper windscreen plastic section - upper section needs to be repainted - primed 11/04/2023 - primed 2nd coat 12/04/2023 - painted satin black 13/02/2023 - mirror fitted and removed to allow painting - 2nd coat of satin black 15/04/2023 - clear satin lacquer ordered 15/04/2023 - windscreen surround fitted 25/04/2023 - DONE
12. Gear lever (I want to make one that looks like the one in the video)
- bright steel bar ordered 17/11/2022 - bar arrived 22/11/2022 - turned bar and made gearlever 05/12/2022 - lacquered 06/12/2022 - designed and fabricated locking feature 17/01/2023 - relacquered 21/04/2023 - DONE
13. Design and fabricate solution to boot leak when boot is open
- made wooden template 03/11/2022 - varnished 04/11/2022 - first attempt 12/11/2022 - version 2 wooden template readied for GRP mould 13/11/2022 - GRP mould looking good, I've used some P40 to make the mould more accurate 16/11/2022 - Used P38 on mould 18/11/2022 - smoothed mould and coated with PVA 19/11/2022 - gel coated 20/11/2022 - cloth mat laid 20/11/2022 - 300gm grp laid 21/11/2022 - part was removed from mould 21/11/2022 - P38 (1st pass) used to fill gaps in part 21/11/2022 - wet'n'dry used to smooth part (1st pass) 22/11/2022 - P38 (2nd pass) 22/11/2022 - P38 (3rd pass) 26/11/2022 - grey plastic primer 04/12/2022 - painted and smeared clear gel smooth 11/12/2022 - black pvc edge trim ordered 28/01/2023 - clear coat 29/01/2023 - sprayed rubino rosso 01/02/2023 - clear coat 02/02/2023 - attached pvc edge strip 02/02/2023 - attached the washer tube under the water trap 02/02/2023 - made wooden undercover to neaten the washer tube 13/02/2023 - undercover attached to fibreglass using epoxy resin 20/02/2023 - 35mm exhaust clamps ordered 21/02/2023 - made first bracket to secure watertrap to rear roll bar 03/03/2023 - made the second bracket and added securing screws to watertrap 04/03/2023 - painted brackets 05/03/2023 - lacquered brackets 06/03/2023 - watertrap fitted to boot (tube to be secured) 06/03/2023 - secured drain tube 19/03/2023 - DONE
14. Design and fabricate solution to keep boot open
- ordered 6mm stainless steel rod 25/01/2023 - ordered 5.9mm ferrule foot 25/01/2023 - cut and formed aluminium foot stay 26/01/2023 - ordered 6mm Terry tool clip 26/01/2023 - started "stay rod" solution 01/02/2023 - ordered spherical bearing 02/02/2023 - machined aluminium block to accept spherical bearing and fitted bearing, rod and ferrule 04/02/2023 - all fitted and secured 05/02/2023 (see video) - DONE
15. T-piece for washer jet
- bought 19/11/2022 - added 03/03/2023 - DONE
16. Replace under-bonnet connectors for weather-resistant connectors
- parts bought 21/11/2022 - I need a set of Econoseal jaws (ordered 07/03/2023) - connectors made 19/03/2023 - DONE
17. Design and fabricate front crash bar solution
- used 10x40 aluminium bar left over from seat spacers 10/11/2022 - locking nuts added 15/12/2022 - DONE
18. Design and fabricate front undertray securing mechanism
- undertrays and front ducting fitted 15/12/2022 - DONE
19. Tidy interior carpeting around rear window
- sorted the trim 18/04/2023 - DONE
20. Buy some foot mats
- bought 25/10/2022 - DONE
21. Make or buy interior carpet for boot
- bought samples 27/10/2022 - bought carpet 02/11/2022 - glued carpet in boot - glued down loose carpet all around the car 22/04/2023 - DONE
22. Investigate connecting heated rear window to heated rear window switch
- I tested the rear window and it has a very large resistance, so it looks like it won't work - DONE
23. Straighten annoyingly crooked front air dam chrome surround and straighten screws
- tick 25/10/2022 - DONE
24. Secure washer jet tubes to underside of bonnet - ordered P clips 28/01/2023 - added 03/03/2023 - DONE
25. Tighten screws on headlamp surrounds and tidy up the rubber - tick 26/10/2022 - DONE
26. Check the fuel gauge and wiring. It seems to be reading too low
- ballast resistors balanced 16/04/2023 - DONE
27. Check all the warning lights. Some may need modifications to the circuitry
- all appear to be working correctly, and wiring diagrams have been amended 16/04/2023 - DONE
28. Sort the bonnet securing pin and release hook.
- release hook pushrod secured 14/11/2022 - DONE
29. Make frame to lift the front of the car.
- most parts fabricated 20/11/2022 - bar to fabricate jack saddle arrived 22/11/2022 - saddle made 23/11/2022 - frame welded 24/11/2022 - frame primed 24/11/2022 - completed 26/11/2022 - DONE
30. Lift car on lifting frame
- done 26/11/2022 - DONE
31. Add weatherseals to doors.
- driver's door done 16/01/2023 - passenger door done 23/01/2023 - DONE
32. Swap door handle bolts for longer ones (door handle fell off as screw was too short).
- driver's door done 16/01/2023
33. Adjust trim fitments on main console
- used Milliput to improve the area around the glovebox 20/03/2023
34. Make spacers for upper trim on door cards
- both doors trimmed 24/01/2023 - DONE
35. Investigate adding caster to the front suspension
- ordered adjustable caster / camber plates 11/03/2023 - paid customs and other taxes 31/03/2023 - camber/caster plates fitted to car 04/04/2023 - DONE
36. Add locking pin to bonnet and adjust locking pins
- ordered locking pin from @spursfaninacoupe 17/02/2023 - fitted and adjusted pins 20/03/2023 - DONE
37. Sort out the massive gap at the top of the doors
- trimmed roof lining, made and primed metal filler piece 08/04/2023 - stuck filler pieces in with epoxy resin 09/04/2023 - used Milliputty to smooth the gaps 10/04/2023 - painted filler pieces 11/04/2023
38. Add plastic under tray at front under the bonnet
- made LH plastic piece and metal securing straps 09/04/2023 - fitted LH plastic piece 10/04/2023 - made RH plastic piece 11/04/2023 - centre section made, but requires reinforcement - reinforcement strip made and painted 13/04/2023 - all fitted and removed to allow paint 15/04/2023 - all parts fitted and aligned 16/04/2023 - DONE
39. Tracker to be fitted
- booked for 19/04/2023 - tracker fitted 19/04/2023 - DONE
40. Adjust gauges so they look correct when viewed from driver's seat
- fuel gauge adjusted 20/04/2023
41. Swap voltmeter for clock, as the clock consumes 60mA
- voltmeter ordered 20/04/2023
42. Add AM/FM aerial
- did not go well - touched the body with the aerial amplifier and fried the radio - asked CarAudioStuff if they can supply a new motor unit 20/04/2023 - new motor unit will be despatched on 24/04/2023 - connectors are not the same - e-mail from CarAudioStuff confirms that the connectors can be used - 25/04/2023 - all connected and working 26/04/2023 - DONE
43. Fit tracker
- tracker fitted and lifetime subscription paid 19/04/2023 - DONE
44. Make pin to fix glovebox lock
- pin made on lathe 24/04/2023 - DONE
Take the car for a drive