Indicate The Correct Way

 

Back in October last year I settled on some indicators that I was really happy with, aesthetically. And after stripping them down and adding an additional wire for an earth (fibreglass body remember) I went around provisionally making attempts to fit them. Whilst they are relatively small and subtle the threaded section was not long enough to pass through the body tub and fix in position with the nut on the back. That and the fact each position on the body for the indicators is curved and has a non flat mounting face, which would sit them at a weird angle. I initially started making small offcuts of heater hose sliced to an angle that might have allowed me space the retaining nut slightly and create a fixing…. However it was all a bit sloppy and I wasn’t happy with it all. 

So my next attempt was to use some threaded tube to create a mounting spigot. I have painted all the casings and sealed the lenses with some silicone to reduce any water ingress that will degrade the bulb holder and terminals. Then after I was happy with the position against the bodytub I opened up the holes to the same as the outside diameter of the threaded tube 13mm. I have threaded each indicator into the tube section first and marked the stop position, so that when fixed onto the body they will align in the correct position, then I made up some small rectangle plates to be welded to the threaded tube.

The first attempt I welded the tab to the end of the threaded tube, but that then protruded the indicator to far out from the body for my liking so after a little faffing around I relocated the mounting plate to about halfway along the threaded tube. I obviously did this on all four indicators and when I was happy with the positioning and fitting I simply bonded the mounting plate through the body with a great dollop of PU sealant on the back. 

This has worked exceptionally well and once cured it leaves me a small spigot of threaded tube sticking through the body tub and will be a perfect fixing for the indicators. The protruding section will easily paint the same colour when it comes to that task later on down the line and overall I’m now really happy with how this are fitted and look. 

The fixing back plates on the front two indicators had to be bent and trimmed a little to accept the curvature of the body but the PU sealant (when cured) will hold them firmly and will also get painted to blend in. 

The rear indicators have bonded into the boot area also extremely well and both look perfect for the desired look I’m trying to achieve. So overall I’m now really happy with the fixing of these and they should be more than durable for the abuse they will see from the weather and general road thrash.:

I have also took the chance today to paint up all the bits from the last update (radiator mountings) and now that is “potential” fitted for the final time…. Fingers crossed. 

I hooked a battery up to the fan wires also just to confirm that it actually worked…. And it does, phew! 

Getting Hotter So Cooling Down

 

Sorry for the long delay since the last update, life has been busy and expensive recently, so haven’t had much time to progress. Still here we go with some updates. 

The original Spitfire radiator was all sorted via a third party well over a year ago now so it’s all pressure tested and ready for use. I need to make some new fixings and mounts for a cooling fan as the fitment will be nothing like the original setup and mounted into the chassis in a totally different position location. The fan itself is seriously overkill for the application, however I got it a good while back from a mate for only £25 and will certainly be sufficient for the job… and I have learnt from my Cobra build it is better to be over effective rather than under. I started off making four brackets, from 2mm alloy that will wrap round the side of the radiator, these will be held with some cotton/rubber bobbins through the original side m6 fixings. These rubber mounts will also act as vibration absorbing for the radiator on the chassis brackets (that still need welding on) so reduce the risk of fracturing the radiator. 

The four brackets are fairly straightforward to fabricate and we’re all made in a cardboard template first. Once in the metal they fitted perfectly and have been painted up to look good. I am a tad concerned about the size off the cooling fan and the lack of natural air flow getting restricted through the radiator.. however with me converting to a thermostatic switch control this should allow hours of stationary running the engine (without natural air flow) and the fan will kick in and out accordingly.. and as mentioned before, it’s pushing significantly more air than required as it really is much bigger than requirements for the job in hand.

Next I have to carefully plan the side fixing plate which will be welded to the front of the chassis leg. This is simply drilled to accept the other stud of the rubber M6 mounts and then bolted on with some nylock bolts. Once I had both sides mounted I had to start planning and measuring up the fixing point on the front of the chassis legs. When I was happy with the positioning I marked up where the right angles of the brackets located. So first off I intended to weld these brackets on, however this would not allow future removal of the radiator for whatever reason. I considered fitting a few rivnuts either side so I could bolt the brackets to the chassis legs….. however access for the drill and setting tool for the rivnuts was impossible so a new plan was needed. 

I used some off cuts of 6mm steel bar to create a plate that could be welded onto the chassis legs, however these plates would have two M8 studs welded on to then allow me to bolt the brackets on from the front nose cone. You can see pictured below one of the new stud brackets fitted to the radiator bracket for the offside. 

With these two stud brackets fitted it was back to marking and measuring up the welding position on then chassis. I started to weld them into place, however I ran out of gas for my welder so I just did a few tack welds to hold as opposed to lots of pigeon shit welds that would not hold. I’ll have to come back and finish these welds off along with tarting it all up and making it look pretty, however the plan of removal for maintenance was working fairly well. 

I was able to pop the full radiator and fan application into position now, and I’m fairly pleased with how it all looks. Access from behind to fit the coolant pipes will be straightforward and access to the front bolts for the brackets is also fairly easy. I will have to revise my front grill idea now as I also need to make this removable to access all of this should I need too. 

I intend to get a header/expansion tank that will be fitted to the bulkhead which will now be the high point within the cooling system to help it bleed and circulate nicely. This will be fitted with a pressure cap of the correct value and also a cap on the original radiator with a higher pressure release value as a reserve contingency just in case. 

Im happy with how this has gone and although the radiator is fixed extremely well I’m also considering adding a support bar from the top of the radiator side brackets back onto the chassis tower mounts just to belt and braces everything really, when the system is full it could be a little top heavy on the fixing studs so they will beef everything up. I have some metal bits ready but will have to wait for welding gas again now. 

I have a few other bits on the go, but cant update you on those bits until they are done and again they will need gas for the welder… sit tight for another update soon!

Phat Ass And Mud Guards

 

Since I have had the chassis rolling and the body fitted I have never been 100% happy with the width at the back end. I first noticed the potential issues when fitting the adjustable radius arms and my measurements for the brackets was significantly different to what was advised within the build guide. This I can only presume is the difference between using Spitfire running gear against GT6 running gear with a rota flex rear drive shafts. Still more than one way to skin a cat as such. As you can see pictured here the width of the car on standard spitfire running gear and my knock on wire wheels. 

Solutions to this issue are not going to be easy or relatively cheap. My options to increase the track is to space the hubs or change the offset/backspacing of the wheels. Changing the backspacing of the wheels will be very very costly due to the specific size of the wheels which would then require a new set unique to my requirements so easily close to £2000…. Which I don’t have. Also I love the little 13” wheels I have and they will technically keep the speedo reading accurate as they have the same rolling circumference as the original Spitfire wheels and it would be easier to find another set of wheels the same size secondhand again should I need to in the future. 

So my chosen option is to space the hubs by a significant amount really… 30mm each side!! Wowsers!  I have researched this option in great depth and have seen some really bad examples and issues off the back of bad installations, but with the correct install using the correct components then I’m struggling to see what issues will arise really. Physics is physics after all! So I have specifically ordered hubcentric spacers machined to my 4 stud PCD with upgraded M12 x 1.5 studs as opposed to the original 3/8th on Spitfire. I also now intend to replace the wheel studs in the Spitfire hub to bigger more beefy Freelander M12 x 1.5 studs despite me already replacing these for original replacements earlier in the build. The advantage being I will then be able to torque the spacer to the hub and the knock on adapter to the spacer using around 110Nm as opposed to only 65Nm on the smaller studs. I will need to get some open wheel nuts with a 40degree taper as opposed to the ones in the picture here which are 60degrees, as they nip up ok but aren’t seating 100% against the knock on adapter. Also the bigger studs will be less likely to get stretched by over tightening and thus loosing the tensile strength and potentially a wheel when driving. This genuinely is a fairly common problem with Spitfires and if you look back in my blog to see the pictures of the previously replaced studs you can then see the effect of over torqued nuts!! 

So now with the two hubs provisionally fitted you can now see the increase in track width this has given me, and wow it is soo much better than previously. I am much happier with the stance of the car now and I hope I don’t live to regret such a drastic spacer fitted. However a chap I work with has a Ford Ranger (I also own one on standard wheel size) and he has 20” wheels spaced 50mm each side which looks barbaric in my opinion. But he has been using it daily for a good few years now with no issues. Yes it’s a 5 stud pattern as opposed to 4 but as I said previously the correct components and physics is physics which can’t be denied. 

With the rear wheels now spaced and set correctly I was able to now make a start on fitting the mud guards. This has been a real pain in the arse from start to finish (and I’m not finished yet) and I’m really out on my own when it comes to fabrication and fitting. The build guide is extremely vague on fitting these, and what little information on the internet from previous builders all state they didn’t “beef” up the fixings enough and have lost mudguard during a drive…. Let’s see if I can nail this first time then!

I started off welding two bits of plate on each side of the rear drum back plate. I was intending to fit the two front guards first however after fitting the rear spacers I am now considering spacing the front wheels also to give me a tad more steering angle. The current setup sees the wheel voiding the body with about 1.5 turns of the wheel and if I was to space the front wheels slightly (about 20mm I think) should see me get a significant further turning pitch before voiding the body with the inside face of the wheel. I will be restricting the rack once all this is concluded so that I can turn lock to lock without fear of causing issues. 

With the tabs welded on as my fixing point I have used some 3mm flat bar to create the frame to mount the mud guard. It has been a real pain in the bum if I’m honest and to make a second for the other side keeping the same spacing and symmetry is a tad daunting, which I’m not looking forward too… still onwards. I can’t really go into detail as to how I made this frame, it was just a tedious process of bending, adjusting, trial fitting, jacking up, wheel on, wheel off etc… etc… however the one side is starting to come together. If you see pictured here that I have added some strengthening sections welded down the two uprights and these take out soo much vibration and wobble that was previously present and have massively beefed up the whole structure which I’m very happy with, again to replicate all this for the other side is going to keep me awake at night as I want the arches to both sit evenly and equal each side. 

With the arch resting on the frame and some manipulation of the metal here and there I was getting much happier with the fit and spacing of the arch. I had cut some little notches out off the fibreglass to allow for the fitting and I have also sanded and got an even radius of the arche edge all the way round. Some fine tuning will be required when it comes to the paint, but the cut edges are now all acceptable for trial fitting.

I still need to physical fit/bolt the arch to the frame but my intention is to use some long pan head bolts spaced between the arch and the frame using some tick wall rubber hose to act as a slight dampener to help reduce any vibration issues when driving and to give a small amount of flex should the wheel kick up a rock or stone when in use. I’m fairly happy with how this one is fitting now, but again I’m daunted and frustrated to recreate the same for the other side. I will just plod on when I have time and update you all as and when I can. This is progress, but it just doesn’t feel as satisfying to me to get this done. 

I have over the past few weeks aged an extra year which has allowed me fit some presents that I was given (under instructions from myself naturally) so on go some mirrors that I have been looking at for a while… not a bad gift for £40 really. The same units as fitted to Aston Martin DB4/5 and some Zagatos also but despite these costing only £40, I know for a fact that some Aston Martin owners are happy to pay more than £100 for these exact units…I think £40 is a fair and acceptable price without paying the dick swinging tax…. And they look great along with actually being fairly practical!! I also have some leather boot straps that match the ones I fitted to the bonnet, but I’ll save fitting those for another day. 

That’s it for this update, next one soon I hope, feel free to gift me money so I can buy more bits I need, just message me for my bank details or put cash straight through my letter box. 

Belt Up And Park Your Seat

 

So this update is primarily concentrating on the seat belts and the associated fixing bolts. I managed to drop on again on eBay and pick up some suitable four point harnesses which are very similar to the Cobra. I specifically wanted the aero style rotary clasp and black webbing, so being a tad specific I have been keeping my eyes peeled for some time for some to crop up at a reasonable price, and I managed to get a pair for only £50 which is a huge saving than if I purchased them new and direct with Willians. 

The lower two strap fixings are fitted with eye bolts the inner of which utilises the original Spitfire fixing point on the chassis. The outer one is simply drilled through a bracket that was installed when I put the chassis outriggers and out rails on and then the spreader plate is fitted underneath allowing the eye bolt to bolt through from above. I’m going to fit some sound deadening pads to the floor pan sections under the seats, I fear this will be a tad boomy if not. The under seat void is going to be a real bummer for loosing stuff, as I’m fixing both seats without runners, so I might make a little baffle plate to stop stuff rolling around and getting impossible to access because of the seat position. 

Next was to move onto the top fixing positions, which unfortunately I didn’t really photograph or document very well, however I’ll explain my process and you will see from the images how the basic structure was made. 

I started with a length of flat bar steel (3mm) which creates the horizontal and this was cut to length and curved each end to match the body tub. Remember my rear bulkhead is 2mm steel as opposed to plywood so it already has a good tensile strength and I’m just beefing everything up and adding some bracing to help absorb any impact that it might have to deal with. 

Once this was cut I had to define my position for the top two eye bolts. With the seat roughly in position I measured each bolt equally off the centre line of each seat back and at the height that would keep the fixings below the rear seat squab. Then it was easy just to drill a small hole through and marry up with my rear horizontal brace. I specifically made sure that the measurements allowed the fixing holes on the rear brace to be on the horizontal centre line so with the spreader plate behind also giving the most strength to the setup. I simply mirrored my fixings on the offside to the nearside to give me both sides, then I moved onto making the whole thing solid and structural. 

I dug out the pipe bender again (Christmas money well spent a few years ago now) then I had to put a small curve into each support tube in order to clear the petrol tank. 

I learnt from last experience to mark each tube equally with masking tape, then by positioning each tube in the same place each time it gave me a fighting chance of making a pair the same. They turned out really well and I was pleased that I only had to put a slight radius on the one end. Triangulation is the strongest form to create strength, but I could use the tubes without a slight kink as they voided on the petrol tank, which is as low as possible already to keep the centre of gravity down. 

With the two tubes bent I was able to cut the mitre into the bottom end and weld it onto a 6mm steel fixing plate, which is then bolted onto the chassis using the original fixing positions on the rear suspension cross brace. The other end of the tub was then tacked to the rear horizontal cross brace I had just made so I was then able to remove the whole rear bracing and beef up all the welds along with tarting it all up with some paint. 

With both braces in place and painted it was really really solid and should be more than sufficient for its purpose. However I hope I should never need to test this functionality…. Better safe than dead haha. 

The next niggle I had was a little knocking where the rear braces bolt down through to the chassis. When I fitted the boot floor I kept everything as low as possible to keep the petrol tank down as mentioned previously. This in turn has allowed the boot floor to rest on the chassis mounts, and despite being bolted through and torque down tight it was still allowing a slight tapping/knocking between the flex of the alloy boot floor and the chassis top mounts when giving it all some movement. I was aware of this issue prior to the seat belt fixing braces, but this has now accentuate it slightly and I was reminded when I was giving it a bloody good wobbling when I fitted them. 

I have solved this problem by unbolting the lower fixing bolts from the newly made bracket which has allowed me to slide some strips of rubber between the chassis mounts and the underside of the boot floor, then when everything has been bolted back down I was able to stand in the boot (on the rear diff) and bounce up and down with no knocking or tapping whatsoever…. Great success!

Next on the list of jobs was to fix the seats into position. The seats have to be secure obviously but not to the same extent as the seat belt fixing braces, still I belt and braces everything I do so I doubt it will be any different for this task. 

I started off with some strips of flat bar steel (4mm) and after offering the seat shell roughly into position I started making some lengths to support the front and back of the seat shell. I have cut the prop shaft cover so that it doesn’t act as a spacer on the one side for the brackets as I’m trying to keep the seats as low as possible and 1-2mm higher on the one side all adds up and would technically not sit the shell flat. Once these strips were cut they have been fixed into the chassis and outer sill but using countersunk machine screws as the seat shell would sit on the bolt heads if using a standard bolt. Again these don’t have to be super strong as such because any force acted upon them is the weight of the seat shell only, the body weight mass is transferred to the harnesses and the seats would stay in position as they have little mass in comparison to a human. 

Next I added two further strips of flat bar steel to give more support for under the seat. I cut them to length and welded them into position so that the seat frame becomes one piece ready for painting. I could then fit the seat into position and really get a flat solid mounting position which felt much more substantial. I made four fixing bolts through the seat shell into the now complete seat frame and secured using some M8 bolts and rivnuts. This will allow me to remove the seats easily should I want or need to later on. 

Now I was able to fix the seats shells and the new harnesses and really get a feel for the driving position overall…. I was very happy to be fair. Yes it’s bloody tight and small but that is the nature of the car. I will have to be friends with whoever is in the passenger seat as they will be very close… but overall it feels very engaging and I think it will give a rewarding driving experience. All switches are in easy reach and visibility is good with all the gauges and warning lights. I’m extremely happy that I fitted a removable steering wheel boss as this has made getting in and out significantly easier. Just the passenger side to do also and then I can start making some commitments on getting the seats trimmed, along with some interior  trimmings that I have a few ideas for also. 

A Festive Blowout!

 

With the new year looming and some much needed funds received as Christmas gifts I have blew it all with very little to show for it really. The picture here shows you what £150 will get you on the Rimmer Bros trade account, along with frustration and disappointment added in for good measure. Firstly I really wanted (not needed) a fancy looking rocker valve cover and whilst these are not really massively expensive they aren’t cheap either… apart from the quality and finish. 

Whilst these covers are not made by Rimmers so they can’t be directly responsible I would have just expected better for the money. Firstly no baffle plate in the new one compared to the older original. Secondly the mounting face on the new one is just a flat flange to accept the gasket. If you look at the older unit you can see the return pressed into the perimeter to give the gasket a channel to sit and expand into and logically seal. The new unit has now forced me to use RVT to bond the gasket onto the cover, which again didn’t fit well at all. This now “should” seal when fitted and torqued correctly, however in this day and age when you can 3D print, CAD and machine anything from anything I just would like to see a little more effort from these manufacturers of aftermarket parts… but maybe my standards of expectation are extremely high? 

So my next gripe with my purchases was the quality of the packing from Rimmers. Call me old fashioned but gaskets “should” be kept flat for packing and shipping, however in this situation the water pump gasket was just crammed into the box with the water pump and during transit had been ripped, making it unusable. Again this is a trivial issue, but more care and consideration should be taken by these big international companies as it is luck that I already have a number of sheets of gasket paper that has allowed me to continue with the installation today by making a replacement. But onto my further grip with the same supplier is the picking and packing issues…. Again. 

I had to order a number of fixing bolts and fixings for the water pump housing and thermostat housing etc… each of these bolts are slightly different in length ranging from 2 1/4 to 1 3/8 and 1 1/4 etc etc… again with various thread pitches. 

So further frustration when I unpacked my bits and non of the specific bolts were labelled or marked in any way to help identify which was which. Not even written on with pen…. Nothing.  So further time had to be spent measuring and identifying each one. Can’t understand why they feel the need to conduct business like this… I genuinely think I will back heal Rimmer Bros now and give someone else my business from now on. It’s a competitive market and there is plenty of choices out there and I would happily pay more for a better level of service and quality of component. Still meh! Just another bad experience with a leading supplier who won’t give a shit if I could be bothered to inform them. 

However despite all the trivial setbacks I was able to fit the new water pump housing and pump, the thermostat housing with stat along with the original alternator and fan belt. The alternator I have had up to where I work and I bench tested it on the testing machine checking that it was all working ok. The only niggle with it was that the bearings were/are a little noisier than I would like, but to not have to replace it now is money saved on the ever tightening budget. 

You can also see here that I have fitted the replacement valve cover which does look great, however I’ll reserve judgement on its practical uses once I have had a couple of engine run cycles, I have little confidence it is going to seal easily or effectively. 

So my last bit for this update is fitting a couple of bonnet straps that I have had for ages but been putting on the back burner until I had next nothing else to do. I started off changing the fixing bolts to the same style as used in the rest of the build (pan head sockets) so that all fixings are using the same style and the attention to detail is in the whole build front to back, inside and outside. 

 These are really easy to fit just a simple drilling of the bonnet and side panel in the correct position that makes them look ok for the three fixing bolts. 

I did the first strap by eye and in a position that I liked. Then using some masking tape, I made a crude template to mark the fixing position which when mirrored onto the other side gave me a relatively accurate position to drill for the second strap. 

After fitting the second strap and then checking measurements from a strap fixing bolts to the uppermost headlight escutcheon bolt and triangulated back to the bonnet vent corner, then I’m only out by 1mm side to side…. Which I can live with easily, they don’t look uneven and both straps now will keep the bonnet closed and secure when out on the road, just need to get and fit two more to the boot now. 

So not a great deal to update you all on however I’m still just plodding on slowly and surely chipping away bit by bit until I can define the car “finished” as such. So happy new year if you read my blog and some further updates soon to come hopefully. 

History Repeating Itself

So according to my social media it was the 2nd of November 2011 I fitted the handbrake to the Cobra during the build… and by pure coincidence guess what I have fitted today on the Spyder, yep the handbrake. When I stripped the chassis all those months/years back I should have took a couple of extra cuts off of it to help me… however I got very good money for the rotten shell from what I recall so this has hardly been an expensive purchase. I was in contact with SpitBits again and they had a prop shaft tunnel with hand brake mounting on the shelf and this was quickly dispatched to me after I had paid. Unfortunately having no control over the removal from the body I have not really had the exact cut I need. The lower lip section as in this photo is perfect, as it will return down in a vertical position when sat on the chassis. However the other side has been cut a tad short, so I will need to fabricate and adjust it slightly to be of any use to me. 

With some measurements taken from the seatbelt mounting points I set about with the grinder, cutting the panel to my requirements. I had to also weld in some additional metal in order to get a good fit. The additional metal was simply the off cut of the other side shaped and welded into place as shown here on the lower front of the panel. I then marked and drilled two 8mm holes towards the front of the panel down through the chassis which will become my front securing points. The chassis holes were opened up further to a 10mm to accept a riv-nut and then the whole panel can be fixed to the chassis with the two new bolts at the front and two seat belt bolts at the back. I have some strips of neoprene self adhesive to stick onto the chassis top to creat a seal between the prop shaft cover panel and the chassis, and I intend to just put some rubber seal on the back end to seal off against the bulkhead. It shouldn’t get much weather abuse when in use as the road spray will mostly be on the outside of the car as opposed to the centre from underneath.

With the new panel in situ I was able to fit the handbrake and with a little adjustment here and there it was functioning very well…. Considerably more effective than on the Cobra and i haven’t even fine tuned it yet or bedded the brakes in… so I’m really confident this will be more than acceptable for the car once finished. 

Now this is done I can really start to make some fixings and seat positions which I’ve been holding back from, knowing this “might” have an effect on how they finally will fit. So that will be relatively easy I hope when I do that. 

I don’t have the materials to fit the seats yet, so next up was to seal the engine off from the elements from the underside at least. I have cleaned up the sump and give a good covering of bedliner paint (still left over from the chassis painting) and with a new gasket, sump plug and fixing bolts I was ready to fit it all into place. Just prior to that I had to fit the oil pump. This has been checked using a feeler gauge to check the wear tolerance and I have decided that the original unit is still extremely usable as opposed to risking a replacement third party unit that will probably have a worse tolerance than this one, this was put in place using plenty of engine assembly lube but this is where the brakes were put on the task. The three fixing bolts need to be tightened to 11Nm torque and the lowest my torque wrench will go down to is 30Nm. With this being internal to the engine I’m taking no risks with the installation and will hang fire until I can torque up correctly and the same for the sump bolts. 

I have also done some bench testing of the starter motor and with some light cleaning and servicing it is also now ready to be fitted to the engine. This allows me to possible turn the engine over a bit using the battery so I can generate some oil pressure and make sure everything is turning freely and how it’s supposed too, however I still need to get my rockers and push rods before I can set the valve lash and see the valves open and close. I will probably video that when I do it, but I want to familiarise myself with the cam shaft break in procedure first as so not to risk any damage. 

 

Fog Light Fabrication

 

So today has been an awesomely productive and creative day. I started off rolling the car out the garage and putting back in face first, to give me more room to work around the back end. I have started to fit and plan out my rear end lights and fog light which has took some fabrication and modifications of some lamp units for an epic result. I started today by fitting the rear stop/tail lights to the guards themselves. I still need to fabricate and fit the brackets to hold the mudguards to the car itself so this is now on my radar to get sorted soon. The rear guards have the mouldings to accommodate a range of different rear lights. I have opted for the same as on my Cobra the Lucas 692 units, which are lovely lamp units to look at and are a perfect fit on the mudguards. The Lucas 692 units are shared on many cars of the era and are even the standard rear light units on the Aston Martin DB5 so it is certainly good enough for me. 

Fitting the rear lights is fairly straightforward. Start off by determining the centre point for the light and then I cut a 30mm hole to take the light unit but leaving a little movement to seat the light square and even. I then had to drill two 5mm holes for the fixing bolts and these are just simply secured from behind. I might consider making a weather splash guard for the underside of the mudguard as the electric terminals will take a fair old bash from the elements here so, prevention is better than cure in my opinion. The second mudguard is exactly the same process as the first as these are symmetrical parts and are not handed offside and nearside. Last bit her was just to bolt each light into the mudguards and rest on the rear wheel, waiting for the fabrication of the brackets.

So next up is an idea from the depth of my brain. I want to create a custom rear fog light that also incorporates the rear number plate light however it needs to all look on trend with the other rear light units and more importantly practical. I had an older Lucas 692 unit without a reflector so my idea is fairly simple, I intend to remove the centre section that holds the bulb and that should allow the bulb holder of the front unit to fit through. This will create a double back mount as such with a reflector on the front which will be used as a fog light. Then with some tactical cutting and fitting of a led bulb of the back unit will allow white light only to shine down to illuminate the number plate and the fog light will work independently without any light crossover. 

The removal of the rear centre section was fairly easy, it’s not going to be used as such so I just set about it with a hacksaw and cutting it away slowly to create the centre hole for the front light unit to fit through. I opened the hole up slightly with my dremel tool and as you can see pictured here it will fits together fairy nicely. The next step was to create the opening on the lower section for the light of the white led bulb to shine down onto the number plate. This I have just drilled a 6mm hole either side of the centre line and then opened the hole up with a reaming tool in the dremel again. 

So here you can see how I have created the holes on the bottom edge for the light. I intend to cut some clear Perspex or acrlic to make some protection against water ingress but I’ll have to find something suitable later on as I don’t have anything to hand currently. The two units are simply held together with two long bolts that pass through outer light and will clamp the back light plate between the body tub and front light. The front fog lense is held on with the original fixings so it can easily be removed to replace the bulb if needed. The number plate led will also be accessible to be replaced however this will require removal of the whole thing from the body. 

I have temporarily wired in an led and passed the wires through the centre hole so I can make sure my idea is going to work so next up was to mark and cut a hole in the rear of the body. A 30mm hole for the centre spigot with two 6mm holes for the fixing bolts either side.

I’m really really pleased with how this has turned out, I love seeing an idea through to the final result which creates something truly unique and yet looks completely normal and original to the vehicle. I still have a fair amount of fine tuning to do still but overall you can grasp what I’m trying to achieve as an end result. With everything mocked up and my number plate masking taped onto the body the whole thing is working perfectly and looks flipping awesome! I’m going to also now make a number plate bracket that clamps between the body and fog light housing which will be a nice solid secure fixing point for the number plate. So lots of little snagging jobs to sort now before I can conclude this little section finished but I’m exceptionally happy with the result… and most people won’t give it a second thought when they see it.

Lastly for this update I’ll share this picture of the car on the drive…. I must admit I’m really liking the big grill opening with the style of the car. Despite still under construction my Jag mk2 grill similar to Paul’s car, I’m going to have to decide what a I want and make some final decisions soon. But overall the whole thing is looking bloody fantastic… can’t wait to go for a drive.