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A Light At The End Of The Tunnel ? ....


Guest robinj66

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Guest robinj66

This may be of interest to those of you aiming to put an older monocoque kit through the SVA but it is a bit long so get yourself a cuppa before you sit down and read it.

 

I had my test last tuesday at Gillingham. it rained for the first time in about a week and the tester was 3 hours late. he then proceeded to start by telling me how these "older kits" had loads of sharp edges. Following a little verbal intercourse, things settled down and information flowed a lot easier.

 

The car had been for an MOT the previous Friday and it was apparant that the (virtually new) 38 DGMS carb was going to be a problem. On one side the HC was around 59 and on the other, betweeen 4000 (no, not a typo) and 2500. Managed to wangle a pass by hook & crook and blew out the idle jets over the weekend. That seemed to clear a blockage but meant that the idle mixture was only set roughly. Of course it passed with 495 & 1056 ! :rolleyes:

 

Handbrake surprised me by passing but the brakes only gave a 57% reading when a pass is 60%. Ian (the tester) believes this is simply the brakes not yet bedded in but I hope i haven't overdone it on the estimated design axle weights (525 & 650).

 

Speedo is a Vapor unit with a single magnet attached to one driveshaft. It was calculated simply by measuring the circumference of the wheel, a process which I thought was so simple that it was bound to be miles out - it was, of course, spot on <_<

 

The car failed on 9 items :

 

The harnesses don't have a label on them so I have to find proof that they comply with Euro regs. This is something which i would urge others to check. [Mine were made circa 1992 so would not necessarily meet the latest regs]

 

One of the rear tail lights decided to stop working halfway through the test and no amount of tapping/knocking/kicking would resurrect it. (I can guarantee it was working when I arrived at 0800). I have since changed bulbs and it's not that simple - likewise the brake light and indicator are both working so it's not a bad earth. Will have to chase the wires back :mellow:

 

The exhaust clamps were "sharp". Don't worry about the bolt heads which were covered but 2mm stainless bands around a hot exhaust might cause someone a nasty injury :unknw: (can you feel the sarcasm coming at you in waves?) - Apparantly they need to be covered with exhaust wrap (pics)

 

I had used a cable tie around the top of my (Cortina) accelerator pedal to stop the cable popping off. That was held to be "not of a durable lasting material" and needs to be replaced with a jubilee clip or similar. I can sort of see his point but it was deemed OK on my Cobra in 2005 and hasn't come off yet! (see pic)

 

My battery clamp wasn't deemed good enough. (pic)

 

There were apparantly non-blunted edges under the nearside dash including the plastic cover to the fusebox.I don't know how people like PWS and SVC get away with selling such dangerous items :nea: (see pics)

 

The more serious items (for anyone who has made it this far) were more design flaws than build errors (or so i am deluding myself)

 

It seems the accelerator and brake pedals were flexing the mounts and these need to be strengthened/braced. To be fair, these are not things that you would normally see unless someone else is in the driving seat. (see pics)

 

Also the Upper steering column support is inadequate and requires bracing. I have to say I agree with the last three - they do need some strengthening . (See pics)

 

 

To cap it all, I was driving back down the A2 at speed when there was a huge bang and I lost drive. one of the UJ's on the prop had gone (circlip out and hence the joint had parted). At least my newly taken out Insurance (Hagerty) included breakdown recovery so i saved some fuel for the last 5 miles or so home :pardon:

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Hi Robin,

 

You didn't think it was going to be easy did you!!!

With all the work youv'e done what you have left to do should be easy.Bad timing with the weather however you should have finished it 3 years ago when it was sunny :rolleyes: See you on the road soon then.

 

Andy

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I think he's been a little harsh on the exhaust clamps. Quoting loosely from SVA regs 'a side mounted exhaust forms part of the exterior surface of the vehicle' and 'protrusions from the exterior surface of more than 1.5mm and less than 5mm need only have their edges blunted.'

I'm sure you can sort the problems. It's just a snagging list to be worked through and there doesn't seem any major disasters.

 

Nigel

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Guest robinj66

I did (unwisely) point out to him that I had seen photos of the same clamps which had passed at that station within the last couple of weeks (and he is the only tester) - his reaction wasn't good. :vava:

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Hi Robin,

Good sport I guess but probably best not to wind these nice people up eh? :rolleyes:

For under the dash, I used some stiff carpet material (not sure if it came with the Kit as initially supplied by RH though).

Bowed this into a semi-circular (tunnel) shape and screwed it all in. Any nasty edges are then above this layer and out of reach.

Keep at it. Do you have a te-test date yet?

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Guest zoomzoom

Hi

I'm suprised they did'nt give you 18 months for those sharp edges B) B)

 

We might as well blame the credit crunch on you as well <_<

 

 

Cheers marcus (waiting to meet a nice sva man in the near future)

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Guest Jaffer

"I had used a cable tie around the top of my (Cortina) accelerator pedal to stop the cable popping off. That was held to be "not of a durable lasting material" and needs to be replaced with a jubilee clip or similar. "

 

... that's an interesting one... Cable tie being made of Nylon and the moulded ends on many throttle cables would be??? Some cars have plastic inlet manifolds which are moulded from a version of... well you get the picture. :(

 

Jaff

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Hiya Robin,

it may have failed, but I still say well done.

The list isnt long or especially difficult.

The propshaft is a B*&^er tho' I guess sitting around all that time may have dried up the grease?

Second Grizzly's suggestion about the "carpet tunnel syndrome" we've all done that when visiting Gillingham, they seem to like the idea....out os sight/touch, out of SVA!

 

The 2Bs all need the pedal box strengthening by fitting (several!) tubes between the box & a structural body part. Must be a few pics on the Rhocar site.

No reason why you cant do the same with the monocoque chassis.

Exhaust insulation round the clamp seems a good idea......or will they fail it if you use a jubilee clip to hold it on?? :D You can always wrap wire round it....it only has to stay on for a few miles....

 

Cheer up.....you re nearly there.....just in time for winter, but even then there are quite a few sunny bright crisp days when getting frost bitten ears is totally worth it!!

 

Bob

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Hi Robin,

 

Going by your post, have you ever thought of leaving the Legal profession and becoming the next Mr. Haynes :D :D :D

 

The car did sound good though, heard you coming up the A2 :good: . Shows how strong the monocoque is by putting up with the prop going west, that was bad news. Funny how the tester didn't pick up on the last minute scuttle hole 'trimmings' B)

 

Give me a shout when you need the harnesses.

 

Al

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Guest robinj66
Hi Robin,

 

Going by your post, have you ever thought of leaving the Legal profession and becoming the next Mr. Haynes :D :D :D

 

 

Al

 

 

Yeh, I do go on a bit, don't I :p

 

In my defence (M'Lord) I know a couple of people are still building the early cars and I thought some detail might help them not to make the same mistakes did.

 

I have to confess the propshaft was partly my fault. I did have the UJ apart and thought the circlip was slightly suspect when it was reassembled. I did check it ... but obviously not well enough :fool: So, one new UJ later, it's back together and I've finally got around to creating an inspection hole in the side of my transmission tunnel.

 

I've also made brackets to strengthen up the throttle and brake pedals.

 

I too made use of carpet tiles under the dash. I was expecting a right sarcastic comment but not a word B)

 

I have a retest date of 14th October - better start preying for sunshine and a temp in the 80's :D

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Guest MacMustang

Nice write up.

 

If Vosa ever reply to my last letter (sent almost 2 weeks ago) I should get an appointment through for an SVA at Gillingham any day :)

 

Does the guy specialise in kit cars then? I took an American car to Gillingham last year and I have to say the guy who did the SVA was really friendly :)

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I took my SVA at Gillingham in 2002 & have since ridden shotgun carrying spares/tools/tie wraps/gaffer tape for about 5 other kit cars being tested there.

 

Ive seen 3 testers, all of them have been thorough, fair and helpful SO LONG AS you dont give them any cheek. One guy took his brother who did him no favours at all by being sarcastic...result...a fail on brake balance & 3 further re-tests to get it passed.

 

They get all the factory built Caterhams & a lot of factory Tigers from their Plumstead workshop so they have seen it all.

If anything fails, ask thier advice on exactly what they need to see to pass it....they are allowed to give you the answers!!! Also ask if you can fix it there & then ....they all welcomed the chance for a tea break whilke we did some last minute fettling.

 

Cheers Bob.

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