Other than mangling the back end, I did get to; sort out the pedal box, mill out a mounting plate for the fuse box, assemble/wire the relays and mount the hydraulic fluid reservoir.   Still trying desperately to get this back on it's wheels, somewhere safe and the tent down for the winter...

Also buffed up the shroud, as I didn't have the tadpole beading to fit this properly - not to self, buy some metal polish and a buffing wheel - this car is going to have acres of stainless.

Edited October 12, 2025Oct 12 by Jake Gully
added pictyre

Connectors!  having been too tight to purchase a new loom, I've been struggling to find appropriate connectors for the engine loom, dash harness etc.

dash loom - TE/AMP:

Managed to source this from Mouser, but had to order three different parts and stump up £ 12 delivery!

Engine Harness - TE Deutsch DTM04-12P:

Easier to find this on ebay and got a wired male and female plug for £ 10.

https://www.ebay.co.uk/itm/406096207285?

Honestly would have been less trouble to chop the shop connectors off and use my own and probably took well over an hour to find these!

Edited October 12, 2025Oct 12 by Jake Gully
Added pictures

Rear tub fitted with trim.   It's going to need a polish!

My differential breather had been snapped off and, although it was only a push fit plastic type, there was nothing really to grip and pull it out with.    Came out very cleanly in the end, with a stud extractor and, not replaced with a Kit spares aluminium one.

 

Edited October 19, 2025Oct 19 by Jake Gully
Added photo

Few jobs sorted yesterday.   I completed the fitting of the rear tub and trims - glad I won't have to take this off again!

I lined out the inside panels first, having brought new from kit spares.   I brought some extra sheet aluminium to extend these forward inside the driver and passenger footwells.   This will make the footwell a little narrower, but will look a lot neater with the carpet fitted.

leaves sufficient space for the accelerator pedal

Still need to do a little to straighten up the rear edge of the shroud, which looks a little wavy

 

Looks like I may be hitting a site size limit, so no more pics today!  

Few odd jobs today, a little touch up painting, fuel tank sender, finally bent up some aluminium to properly mount the fan.  Also put some protection around the engine bay - for what we are about to receive and all that.

Looks like on the newer Zeros, the fuel tank has a welded in collar, threaded to take the bolt pattern for the sender.   On my old gen 1, I just have a cut out in thin sheet.    The sender comes with a thin nitrile washer, but as I have to use self tap screws to fix, I am a little worried this will not sit tight enough.   I will probably remove and refit with some additional instant gasket for good measure.

That completes the rear end wiring and just the fuel pipe and carpets to go in, plus rear lights when I fit the rear arches.

Moved on to the dashboard and have removed the scuttle, cut the fibreglass dash out to fit the steering column shroud.   While it is off, I decided to paint the inside and will probably fit the wiper motor to save taking this all off again in the near future.   Advise seems to be to leave the windscreen and wipers until after the IVA, though at the moment I just want to get the car built before I lose all the bits!

Hi Jake

Afraid you have hit the normal limit.   We have a limited amount of space available on the host server so we limit each member to 100Mb 0f storage.  You have posted 125 pictures and have hit the limit.   I don't think the planners envisaged anyone being so prolific 😀

I'm not sure if it is possible to increase the limit for a single member, I'll have to look though the system software.

Sorry

Al Richey (with Webmaster hat on)

May I make a suggestion. I notice that the photos are being posted in "lossless" .png format, which gives nice crisp images but take up more space than a "lossy" format like .jpg. For example I downloaded one of the .png images above and used a widely available free program (called GIMP) simply to export the image as .jpg with 45% accuracy. The .jpg is a lot smaller, here is a screen grab of the directory listing.

And here is the .jpg image so you can see the quality.

Can you spot the difference with the original above ??

So one way to solve the problem would be to go through the whole thread and replace all the .png images with lower quality .jpg images. The pics would then take up just one tenth of their current usage, allowing many more images to be posted...... any volunteers ?.

Edited October 20, 2025Oct 20 by Sparepart
add post script

Jake, I was reading your thread because I saw that you are having a remote reservoir for the brake master cylinder. Please can you give some detail about this. Was the remote reservoir setup already used on the donor car?  .. if not what is the source of the reservoir I see in your picture above?..Presumably you need inserts for the master cylinder to connect the two pipes from the reservoir. What is the source of these inserts.? Do you know what "standard" the connecting pipe must meet to handle brake fluid, will just "rubber" do? or PTFE. Any other pertinent information would be appreciated. Thanks.

On 10/19/2025 at 4:45 PM, alanrichey said:

Hi Jake

Afraid you have hit the normal limit.   We have a limited amount of space available on the host server so we limit each member to 100Mb 0f storage.  You have posted 125 pictures and have hit the limit.   I don't think the planners envisaged anyone being so prolific 😀

I'm not sure if it is possible to increase the limit for a single member, I'll have to look though the system software.

Sorry

Al Richey (with Webmaster hat on)

Thanks Al, always pushing the limits!  I would go through and edit all the posts and put hyperlinks in to the photos, but you have a timelimit on edit so I'm unable to go back and change these now.    Happy to subscribe to some more storage and pay a fee if there is an option - everyone likes pictures and the build is just getting to the exciting stage with brakes, suspension and about to put the engine in!
 

 

8 hours ago, Sparepart said:

May I make a suggestion. I notice that the photos are being posted in "lossless" .png format, which gives nice crisp images but take up more space than a "lossy" format like .jpg. For example I downloaded one of the .png images above and used a widely available free program (called GIMP) simply to export the image as .jpg with 45% accuracy. The .jpg is a lot smaller, here is a screen grab of the directory listing.

And here is the .jpg image so you can see the quality.

Can you spot the difference with the original above ??

So one way to solve the problem would be to go through the whole thread and replace all the .png images with lower quality .jpg images. The pics would then take up just one tenth of their current usage, allowing many more images to be posted...... any volunteers ?.

Thanks Sparepart.   Happy to go back and edit them all, either as hyperlinks to a shared album, or rescale them all in irfanview. To be honest I was being a bit lazy and just cropping the shots to reduce image size.

8 hours ago, Sparepart said:

Jake, I was reading your thread because I saw that you are having a remote reservoir for the brake master cylinder. Please can you give some detail about this. Was the remote reservoir setup already used on the donor car?  .. if not what is the source of the reservoir I see in your picture above?..Presumably you need inserts for the master cylinder to connect the two pipes from the reservoir. What is the source of these inserts.? Do you know what "standard" the connecting pipe must meet to handle brake fluid, will just "rubber" do? or PTFE. Any other pertinent information would be appreciated. Thanks.

I made a bit of a mistake, and brought a master cylinder for the clutch and then realised I was reading the Duratec instructions!   Only need a cable for the Zetec clutch - still something for my spare parts bin!   
 

It would be more sensible to get the reservoir that attaches to the standard brake cylinder as this would free up some useful space in front of the firewall and the cutout was already formed in the pedal box.

 

HI Jake

I've figured out a hack to change just your allowance so I have doubled it.  However, I would echo sparepart's suggestion and you should use .JPG instead of .PNG.   Also I know you said you crop the pictures but it is far better to 'Resize' the picture.   As a guide, anything over 750 pixels wide is a waste of time, as the forum software simply shrinks the picture to that size.   Again, as sparepart said, there are lots of free programs available that can carry out these actions.  Personally I use Paint.net on my PC.

Cheers

Al

2 hours ago, alanrichey said:

 Also I know you said you crop the pictures but it is far better to 'Resize' the picture.   As a guide, anything over 750 pixels wide is a waste of time, as the forum software simply shrinks the picture to that size.   Again, as sparepart said, there are lots of free programs available that can carry out these actions.  Personally I use Paint.net on my PC.

If you've got a recent iPhone (don't know about Android phones) there is a method of using the built-in Shortcuts scripting app to set up a 'Resize Image' shortcut so you can do all this on your phone. You can set picture dimensions to say 640 pixel width or get it to ask each time, and get it to save the resized copy to the Recents photos album.  Then select that reduced size photo for upload to the forum. Google for detailed instructions if you're not familiar with Shortcuts.

 

6 hours ago, alanrichey said:

HI Jake

I've figured out a hack to change just your allowance so I have doubled it.  However, I would echo sparepart's suggestion and you should use .JPG instead of .PNG.   Also I know you said you crop the pictures but it is far better to 'Resize' the picture.   As a guide, anything over 750 pixels wide is a waste of time, as the forum software simply shrinks the picture to that size.   Again, as sparepart said, there are lots of free programs available that can carry out these actions.  Personally I use Paint.net on my PC.

Cheers

Al

Thanks Al, a big helpand apologies for causing a nuiscance!