The Build

What happens next?

Diary

Date	Stage
27/3/2011	Found Donor Car
21/4/2011	Started dismantling donor car
27/4/2011	Ordered Kit
19/5/2011	Finished dismantling donor car
21/5/2011	Shell disposed of
29/5/2011	Started refurbishing back axle assembly
16/6/2011	Finished refurbishing back axle
18/6/2011	Kit arrived
21/6/2011	Back axle installed
26/6/2011	Chassis Painted
27/6/2011	Engine in and front suspension fitted
01/07/2011	Brake pedals, servo and master cylinder, pipes cut and put in place
03/07/2011	Radiator and steering column fitted
07/07/2011	Heater modified
08/07/2011	Wipers fitted
13/07/2011	Transmission tunnel modified and gearstick mounted, dashboard trial fitted, front fibre glass floor well trimmed almost to fit (still some work to do)
14/07/2011	Radiator shell installed, bonnet top panels fitted
18/07/2011	Power steering reservoir located and power steering plumbed in
20/07/2011	Petrol tank installed, rear seat belt mounting posts fitted
21/07/2011	Front seat belt posts fitted, heater fitted
27/07/2011	Brake pipes secured
28/07/2011	Front wings trial fitted, radiator shell refitted, picked up leather seats
27/08/2011	Petrol pump fitted and piping plumbed in and secured. Wiring Loom, received.
28/08/2011	Front bumper, brackets painted and bumper fitted.
30/08/2011	Rear wings and back panel temporarily fitted
31/08/2011	Running boards temp fitted
05/09/2011	Radiator header tank and air filter fitted, bracket for ignition coil fabricated
10/09/2011	Rear seat back brackets fabricated and installed so they fold down to give access to the limited boot space
12/09/2011	Exhaust fitted except for the back box
15/09/2011	Headlamp shell fitted
20/09/2011	Front panel cut to size and temp fitted, bottom hose fitted
21/092011	Windscreen pillars filled, front floor fibre-glassed to fit around the auto gear shift
23/09/2011	Windscreen pillars sanded and refilled
11/10/2011	Brackets fabricated and front seats trial fitted
12/10/2011	Sierra seat belt bracket modified and fitted to the Ka seat
14/10/2011	Tail lights fitted temporarily
19/10/2011	Additional securing clips on fuel pipe
20/10/2011	Plywood floor and front fibre-glass floor fitted
21/10/2011	Front seats fitted, windscreen surround refilled
24/10/2011	Collected front shocks, windscreens, bonnet sides and fuel sender unit from Beauford
27/10/2011	Fitted fuel sender unit
28/10/2011	Fitted front shocks
31/10/2011	Door pillars/hinge covers measured to fit
02/11/2011	Bolts fibre-glassed in to door pillars, doors trimmed to fit
03/11/2011	Door pillars fitted. Badge bar fabricated and fitted
04/11/2011	Body prep - lots of sanding
07/11/2011	Front indicators fitted + more body prep
09/11/2011	Dashboard cut out and fitted instrument cluster
10/11/2011	O/S bonnet side fitted
13/11/2011	Planned a centre console
14/11/2011	Mocked up centre console
15/11/2011	Fitted N/S bonnet side, removed the front wing and running board to prep for painting
17/11/2011	More sanding and filling
18/11/2011	More filling and sanding
12/12/2011	Started painting
13/12/2011	Painting
14/12/2011	Painting
15/12/2011	Painting
16/12/2011	Painting
	Christmas Break
15/01/2012	Sanding
16/01/2012	Worked on window winders
17/01/2012	Collected Hood
18/01/2012	Started making luggage rack
19/01/2012	Started work on exhaust
23/01/2012	Fitted rear bumpers
25/01/2012	Lengthened window winder arms
30/01/2012	Fitted window winders
31/01/2012	Wing piping
01/02/2012	Refit wings and running board, cut out interior and door cards, rear fog & reversing lights
02/02/2012	Refit front lights and badge bar. Label all connections on wiring loom.
03/02/2012	Made fibre-glass glove box
07/02/2012	Joined glove box to dash and varnished panel
08/02/2012	Started to take apart Sierra loom
09/02/2012	Continued to take apart Sierra loom
10/02/2012	Isolated the rest of engine loom
11/02/2012	Worked on wiring
13/02/2012	Worked on wiring
14/02/2012	Worked on wiring
16/02/2012	Fitted petrol filler pipe, got the engine to turnover
17/02/2012	Tried to fit seatbelts, bled brakes
18/02/12 - 06/03/12	Wiring installed temporarily (twisted wires)
07/02/12	Rear floor panel installed, fuel filler pipe connected
08/03/12	Filler pipe reconnected! Started car (Hooray!)
13/03/12	Connected rear lights
14/03/12	Connected eyes up (headlights)
15/03/12	Started tidying wiring up, making connections permanent
16/03/12	Finished making connections permanent
17/03/12	Made under tray for passenger side dash
18/03/12	Covered under tray in foam and vinyl
20/03/12	Made under tray for drivers side
21/03/12	Covered under tray in foam and vinyl
22/03/12	Made ducts and vents for demister
23/03/12	Covered Dash assembly in foam
24/03/12	Covered Dash assembly in vinyl
25/03/12	Installed dash assembly and dash board
28/03/12	Cut out holes for switches and radio in centre console panel
29/03/12	Assembled centre console trimmed to fit in car
30/03/12	Covered centre console in foam
31/03/12	Covered centre console in vinyl and trial fitted in car
03/04/12	Installed radio
07/04/12	Installed centre console and connected the switches
09/04/12	Covered trim panels in footwell and installed speakers
10/04/12	Partially fitted hood and glass in rear door
11/04/12	Fitted door cards, made lever for heater
12/04/12	Re-covered undertray
14/04/12	Fitted split windscreen
16/04/12	Worked on interior trim
17/04/12	Worked on interior trim
18/04/12	Worked on interior trim
19/04/12	Worked on interior trim
24/04/12	Fitted windscreen washers and interior mirror
30/04/12	Fitted new Securon seatbelts in rear
01/05/12	Fitted beading around windscreen
09/05/12	Reworked Luggage rack and bumper
12/05/12	Reworked badge bar at front
22/05/12	Made surround for rear bumper support
23/05/12	Anchored electronic ignition, battery securing plates, tidied up engine bay.
24/05/12	Cut and shaped aluminium aluminium trim for luggage rack.
25/05/12	Fitted door mirrors
30/05/12	Tried to trace the electrical fault
31/05/12	Fitted side screens
01/06/12	Fitted stop for the hood rails
08/06/12	Door locks arrived
09/06/12	Door locks and exterior handles temporarily fitted
10/06/12	Striker pins fitted
12/06/12	Door locks adjusted and secured
13/06/12	Covered door cards with cream leatherette
15/06/12	Fixed door cards and covered seatbelt posts in foam and leatherette
18/06/12	HAPPY BIRTHDAY TWIGGY - 1 year since kit was delivered
18/06/12	Cut handle spindles to size and drilled for securing screws. Fitted interior handles
20/06/12	Fixed rear speakers below rear seat
21/06/12	Tidied up engine bay a bit more (cables etc), tightened up wing and running board bolts.
22/06/12	Fitted dzus fasteners to bonnet sides
27/06/12	Took out dashboard to find wiring fault
28/06/12	Put back dashboard!
03/07/12	Window rubbers and cleaned car
09/07/12	Seals to try and make weatherproof
10/07/12	Carpet and interior tidying up
13/07/12	Touched up all the chips in the paintwork from, put cap nuts on exposed bolts
18/07/12	IVA test has come through for 20th Sept
21/07/12	Changed rear seatbelts, installed foam rubber strip on bonnet panels
30/07/12	Cut template out for wing valances
01/08/12	Cut out valances and fitted to wings
07/08/12	Painted valances and made bracing bars
05/09/12 - 07/09/12	Worked on the hood trim and seals to make it a little more watertight
13/09/12	Fitted headlamp rims and door stays
14/09/12	Fitted sides to rear compartment to protect seatbelts wiring and petrol pipe
20/09/12	Took the car for its IVA test - Failed
21/09/12	Started remedial work
22/09/12	Replaced handles
24/09/12	Hinges, body projections
25/09/12	Rear seatbelt bracing
26/09/12	Rear seatbelt bracing
27/09/12	Replaced fuel filler
28/09/12	Booked the re-test - 8th November was the earliest available slot
08/11/12	IVA re-test PASSED
12/11/12	Took the forms in to the DVLA
15/11/12	Appointment for inspection came through
22/11/12	Car inspected
24/11/12	Licence number and tax disk arrived, had number plates made up, on the road
11/12/12	Started on building the trunk
19/12/12	Trunk built and fitted to the car
20/02/13	Won an auction on Ebay for 4 alloy wheels
14/03/13	Trunk picnic table, wine glass holder and champagne bottle holder completed
16/05/13	Fitted spare wheels on the front wings
18/05/13	Made drinks tray/bottle and glass holder for inside the car