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Markbzero Building My Kit Car


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Next job was to fit the inside quarter panels (that's what I am calling them). A simple job but I found the holes for the lower seat belt fixture was in the wrong place so I had to elongate the hole slightly.


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Simple rivets and adhesive task, the sharp edges managed to cut me a few times - where did I put my work gloves!




I had to bend the top tabs by hand using a pair of mole grips, took some time but I was happy with the final edge.

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Before I could fit any of the tunnel panels I needed to fit the differential. It was challenging with only one pair of hands, trying to align the bolt holes and balance the stainless steel flat washers between the fixed chassis and moving diff.




In the end I had to support the weight on a trolley jack and use an old seatbelt fitted around my neck and the diff, this gave me a bit of wiggle room. Happy there was no photographic evidence of this.


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The flat washers allowed me to adjust the diff to ensure it was central. I had all intentions to replace with steel tube cut to the exact size, but in true kit car style its a job that can wait for later a winter mod in 2020. In most of the build I used high tensile bolts and thread lock where required.

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I wanted a brum brum moment so I quickly fitted the steering column, only two high tensile bolts and washers so I won't insult anybody's intelligence.

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Bottom steering bush was worn so I replace it.


Then I sat in the driving seat and went for a drive.

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If I remember the next job was to fit driver side inner panels.


Very easy no difficult bends and good old cleco's.

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Most of may drill bits was now worn and pretty much useless, so I invested in a couple packs of 3.2 mm and 4.2 mm cobalt drill bits. They were exceptionally good, stay ed sharp for much longer.

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Bored of marking, drilling and riveting so I chose to work on something else.


Fuel tank;

Not a challenging task just had to mark the half-way position down the length of the tank and align up with half-way point on the chassis, simple!


GBS told me use adhesive only but that's boring I wanted to build a kit car. So in true kit car style I completely over engineered some fuel tank straps.


I used some adhesive to join the straps to a piece of rubber, and then drill the bottom hole and top but decided to fit riv-nuts to the cross member at the top.


All aligned a little more black 'n' nasty adhesive and the job was finsihed.


One thing, not really related to the fuel tank but very near I fitted some black square tube end caps to stop rain getting into the chassis.

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Rear suspension was straight forward with the exception of fitting them on the wrong side and wonder why nothing would align. Spoke to GBS and search this forum, supposedly there was a batch that had a indicator notch on the wrong side.


I squeezed the bush in using my vice and then put the inserts in most were OK and some I had to file down a few millimeters.


It was the same for the bottom arm.


Next I had to fit the hub carrier, again there is a right and left side and yes first attempt was wrong. Why won't the bolt holes align? Where's the build manual?


Next task was to fit the shock absorbers, GBS supplied. Very easy and quick, all with new high tensile bolts.


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I then fitted the pedals, lost of grease.


These have been adjust since the photo's were taken and I used some flat washers to move the clutch pedal. Dependent on what I was wearing shoes/boots I kept pushing the clutch when braking.


When I test fitted the pedal box I thought it would be easier to fit the pivot bolt from the other side. I had to make a spacer to stop the threaded part of the bolt touching a bush.


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Before I get to excited with progress and fit too many panels I started routing the brake pipes. Brand pipe and new flaring kit, I made a few test pieces to make sure the kit was producing clean ends and remind me on its operation (over 10 years since I used a similar brake pipe forming kit.

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Started from the master cylinder, still waiting for seal kit so I left a more then enough brake pipe.


Two front pipe went through a grommet along the chassis and down to the side panel where I would fix the flexi-pipe later.

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Again until I fit the side panels I just left a piece on pipe, I used rubber lined p clips and stainless rivets. I right angle drill chuck was a life saver, and worth every penny.

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I'll come back to the front brakes later.

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The back brake pipe was fed through a grommet in the side panel, secured inside the tunnel with more p clips.

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I decided to use a pressure switch for the brake lights and this was fitted at the rear, as GBS recommendations.

From the 4 way union I had to make to pipes to fit to chassis and the rear brake flexi's.

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I'll show more when I fit the rear brakes.

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I had to decide if I fit the side panels now or after building the front suspension. After ready other forum comments I went for fitting them now. First of all I used the grinder to remove all the sharp edges left by GBS cutting process. Starting to regret having stainless steel panels a bit.


First fit was held together with clamps and planks of wood. I then measured and marked the hold for the rivets, which I drilled off the car and again with the grinder removed the sharp bits.

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The cleco's provide the stability need to drill other holes before I started to rivet the panel, I use a small bead of adhesive where I thought water or road debris could collect.

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I then covered the panel with cardboard to protect it from the odd bump or son wielding a large tool.


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Fitting the GBS supplied steering rack. First I had spray the unit to prevent rust in the future and protect from the elements.


Used a U bolt with new nylocs and don't forget to fit the plate and the other side a clamp and rubber bush. This was very tight to fit, and again i used high tensile bolts.

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Be careful with the steering rack gaiters, some people have failed IVA because they were rubbing on the side panel.


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Well spotted!

Anyway nothing wrong with Farley's rusks, we always have some spare with fostering under 5's (banana are the best). I'll bring some to the Rhocar tent and I bet they will all be gone.

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