Exhaust Preparation

To be able to fit the underslung exhausts I had two choices due to the fact that the chassis is sitting on tressels since there is no way of mounting the exhaust.

I could put wheels on and lower the chassis to the ground, however this would limit the space underneath to work with the exhaust.

I opted for placing blocks under the chassis, raising it up by 100mm, but leaving a gap for the exhaust to pass through.  I cut up some wood and held the blocks on the tressel using two pieces of 3/4" plywood and multiple screws.  It is still solid to work on, only a little bit higher.

Perhaps if building another, the steel tressels could be designed to incorporate this gap to allow the exhausts to pass through.

I will dry fit the exhaust system to ensure it all works before sealing each joint and fitting the clamps.

Engine Wiring Loom

I plugged in the engine wiring loom to see how it all ran and connected.  I now have to figure out what extra sensors I require to be able to complete.

These are:

Oil Pressure Sensor
Oil Temperature Sensor
Water Temperature Sensor
Oxygen Sensors

I will have to find out where to source these from and what the required ranges are.

I also plan to run a wire to the reverse lockout solenoid up to the dashboard, so I can install the required circuitry to operate it.  Reverse is located next to 5th gear, and so this solenoid prevents you from inadvertently selecting reverse when you are moving above 5mph.

Transmission Tunnel Cover

I used a piece of card to work out exactly where to put the cut out in the transmission tunnel cover for the gear lever.  I used a 60mm hole saw for the hole (Ends up being around 62mm once drilled).  This is large enough to prevent the lever from touching the cover when in any gear while stationary, and hopefully even when driving!  I will bolt the cover in place once I have finished modifying the handbrake cable.  The cable needs to be shortened and will be easier to work with without the cover being bolted in.

Final Gearbox Cover

I have made and fitted the final gearbox cover using perforated sheet.  I don't think there are any more holes that require covering!

Starter Fitted

I bought a starter from GD since I didn't get one with my engine.  It was a very straight forward fit (while the exhaust is off) but it leaves an uncovered part leading to the flywheel.  I had to create another cover to ensure no debris can enter the bellhousing.  I used the same perforated sheet as the other covers I have made.  Only one more hole to cover which I will create over the next few days hopefully.