OK - it's staying like this!   Just need to bend up some aluminium flat bar to securely mount the fan

Scuttle riveted and bonded - just leaving it to go off for a day:

Rivets feel nice and flush and secure with a stainless steel scuttle.

Couldn't resist a quick look with the hood on, looks like it will overlap by about 2 inches over the scuttle, but can't be sure until I trim all the tabs off the front and get it bolted in place.

 

Did a little more work on the pedal box and measured up for the accelerator pedal.   Need to mill the width down to  decided to mill down the pedal bushes to around 13/16".  Bit of a shonky setup as there was nothing square on the pedal and I couldn't properly grip it and keep it square in the vice.

Need to find a shorter bolt for this, but will line up well enough with a little fettling

Few other odd jobs, started fitting the boot panels, deburred, drilled and started fitting the tunnel panels to mark out for the rivnuts before I start carpeting.

 

Even got the tub panel out for a look, it's taken a bit of a beating in storage over the years and needs a fair bit of work to debur all of the edges and tabs - might get a start on this tomorrow as I am very keen to get it out of bent to shape and fitted as it takes up so much space and has too many nasty sharp edges.

Trimmed the scuttle down and have fitted it 3-4 times today.  Few more tweaks to the pedal box, but still not ready to fit this properly made a few tweaks today.

Drilled and fitted the rivnuts for the tunnel top.

 

Cleaned up the tub and bent tabs 

 

This is quite difficult to bend to shape, but I've made a start, using a rolled towel to help with the radiused corners.  No access for clamps so quite difficult to get this right for drilling - really need a second pair of hands.

 

 

I found my extra hands - two US Pro long reach C Clamps.   That changes the game:

Just need to drill and cleco.   Expect it will all pull in tightly as the fastenings go on.

As this is an early body kit, I will need to drill and cut all the holes for lights, wiring, fuel filler, etc.   Also it looks like there needs to be a bit of a v cut to clear the differential.    Quite a bit of test fitting and patient work to come.

Bit of fun getting rear panel into shape and drilled for the clecos.   However, got there in the end and a reasonable job:

I did a test fit, but found that the shroud was too narrow around the roll bar and I had to cut out about 9mm on both sides.   Not before I scraped a lot of paint!

Once I had opened it up, it went on nicely.   Thanks to tips from Richard and David, I was able to bend up one of the roll bar stays to get the tub level.

All seems to go together nicely with the rear quadrants and shrouds.

Although I do have a big gap under the panel and not sure how this should secure.

I have marked out for the fuel filler cap and looked at the fog and reversing light I had.   These are odd sizes and I will probably get a new pair from GBS (contoured fit for the panel) and I also need a number plate light.

Panel removed for now and I cracked on with putting new bushes in to the swing arms, ready to rebuild the rear suspension and running gear.   Also cutting some internal carpets.

 

Carpet kit for early Gen 1 GBS Zero  (10' 6" x 5' 6") - not quite made to measure

 

Having slept on it, I'm certain I have made a mistake with the bottom of the rear panel.   I have folded and mounted flush to bottom of the sides, but there is a big gap and no clear way to fasten, so sure that I need to fold this up tight against the underside of the chassis as with later builds.    The sides will protrude down, below the floor, but this space will probably be filled by the diffuser and I can run some edging strip along the exposed edges for IVA.  There are lots of excellent build threads, but I'm been unable to find decent pictures of this part.

Taking a bit of a break today, but managed to get all of the rear suspension bushes installed last night.    I initially struggled with these, but massively improved after deburring the inside of the bush tubes and liberal use of copper slip.

Also bolted the prop shaft in to the diff, but will still need torquing up once the engine and gear box are mounted and lined up.

Little more fun after work today, but only for an hour or so.

I fitted the tub again, removed the cleco's around the bottom edge of the sides and clamped the floor up against the chassis.   I then marked out internally to trace out around the diff carrier.   With this transferred, I removed the tub and then cut and drilled the floor

A couple of quick cuts with the jig saw and then a little work with the grinder to open this up and take off the worse of the sharp edges.

Once offered back up to the chassis I was able to drill through and fit with clecos.   Subject to truing up with a straight edge I now have the bottom edge of the floor clamped to the sides and will remove, drill and should be able to bond and rivet this up properly.

 

The bottom edge is looking like a doily - I may need to use some extra rivets to blind these holes.

I don't really like the sharp knife edge, but think this may be hidden eventually by the diffuser (after IVA)

Final suspension bush done..

 

 

 

 

Rear suspension rebuilt - all tightened down, with thread locker and paint marked.  Quite a few nicks and scratches, so will need to find a little Matt black touch up paint.

Also did some more work on the tub.   Drilled and cut out the fuel filler and light mountings.  There was nothing pre drilled on my body work.  Lights mounted, but do not like the bolts as these would puncture the fuel tank in a collision.

I will cut the bolts back, finish the rear loom and fuel lines and then mount the tub finally.

Slightly 

Slightly annoyed that the kettle slot does not line up with the bolt pattern - rattles my OCD.

Fuel tank just clears the light bolts, but I need to shorten these back.

 

Simple solution to the light bolts - turned them round..

 

Spent most of the day sorting the fuel pipes, wiring the rear end and sorting the rear loom.   I have now remounted the tub and fixed it, but still need to add the trim around the shroud and bolt through to the stays.  All the lights are wired, but I have made the number plate lead too short.  There's no route under the tank and I need to go around the back.

Slow progress and so much still to go!

Rear tub quarter panels fitted - not as easy as I was expecting as the curve did not quite match up as it met the tub.    Had to get the hammer out and made a bit of a mess on the near side.   The off side was a little easier, but neither is great - will see how it looks after polishing up and, hopefully most will be hidden by the shroud and wheel arches..

NS  (bolt is for clamping while it sets):

 

OS:

 

Not pretty, but all bonded and in now.