Burnt Pig - 356 Pre a Build Thread

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Robneal
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Re: Burnt Pig - 356 Pre a Build Thread

Post by Robneal »

Its Home....

After a long wait the car is now home....Not all the jobs got carried out at Speedster Clinic, so here's a status of the last list with an update of where Speedster Clinic finished up.

1. Take a mould off of the Moulded bumpers and work out a way to fit bumpers to car securely - Bumpers removed but they have not been moulded yet, awaiting a date as to when these will be completed
2. Final adjustment of drivers door and Bonnet fit - Door Panel Fit is now pretty good, with the doors and bonnet lining up with the body, there is some filling to do, but it is as good as it needs to be to get it through the IVA test
3. Rub down body to get rid of all of the moulding lines and make it smooth (I'll be driving it in Gel coat for a while to shake down any build problems before I go to paint and get the interior trimmed) - Body rubbed down and again is now good enough for IVA and will still need final filling and work ready for paint, however it is good enough for now
4. Fit temporary rear fog and reversing lights IVA compliance - Not carried out
5. Install throttle Cable - Installed, but not functioning, needs some investigation as to whats wrong
6. Make and fit engine side tins - Not carried out
7. Repair front screen aperture where it was ground too thin to get the screen to fit, and re-fit front screen - Front screen now fitted
8. Repair round the hole in the bulkhead where the steering column has been moved - Complete
9. Relocate Fire Extinguisher pull to make cable route less severe and easier to operate - Complete
10. Fit internal door handles - Not Complete

Some pictures of the Electric window installation showing the inner door mount and how it is braced off of the bottom of the door to make it stable...

Image20190706_113141 by Rob Neal, on Flickr

Image20190706_113134 by Rob Neal, on Flickr

Image20190706_113124 by Rob Neal, on Flickr

Image20190706_113121 by Rob Neal, on Flickr

Some Images of it leaving Speedster Clinic

Imagereceived_467518980715145 by Rob Neal, on Flickr

Imagereceived_1288839224606118 by Rob Neal, on Flickr

Imagereceived_3072104246148204 by Rob Neal, on Flickr

And a few Pics of it ready to push it into the garage

Image20190706_113204 by Rob Neal, on Flickr

Image20190706_113158 by Rob Neal, on Flickr

and one with a Painted Space Saver wheel propped up against it to see what it would look like without the red wheels

Image20190706_134711 by Rob Neal, on Flickr

So where does that leave me with the list of things to do before IVA

New list off the top of my head, but I really need to have a proper look over the Car to finalise the list

1. Make Bracket & fit Temporary Rear Fog / Reversing Light
2. Fit interior Light
3. Fit Electric Window switches Temp
4. Fit Door Courtesy Switches
5. Re-Fit door Frames as need to move back by about 10mm
Image20190706_113640 by Rob Neal, on Flickr
6. Fit strengthening panel to inner door skin as the door inner is very flexible and when Speedster Clinic tried to fit the internal door handle, the fibreglass is really not sturdy enough to support the operation of the handle - Speedster Clinic are developing these panels now as they see that this will be required on all Coupe Cars. Mark Staples that is also building a Speedster Clinic Coupe has already got passed this stage and sent me the picture to show how he added a steel internal door panel he also used it to mount the manual window winder on it.
Imagedoor inner by Rob Neal, on Flickr
7. Plumb in Oil Cooler and Oil Cooler Fan switch
8. Fit Fresh air intake to heater at the front of the car
9. Fit Fuse board and Relay board ready for wiring.
10. Mount Emerald ECU
11. Mount indicator stalk
11. Re-build dashboard with all clocks and Switches in it
12. Make and Fit engine side trim
13. Sort throttle cable operation
14. Adjust clutch
15. Build bespoke wiring loom for car - I have found a local guy, Stuart that builds wiring looms and undertakes wiring for Harry Harpic's air-cooled specialist in Southend and he is going to to build the loom specific to my car and then bind it all. The wiring specification I have lists all of the components and also makes provision for some items I may well add at a later stage.

So Stuart will start in August with the wiring so need to get my skates on to get all of the pre-requisite stuff done before he starts.

Am sure to add to this list over time but will track this as progress for now
Last edited by Robneal on Tue Jul 16, 2019 8:14 am, edited 1 time in total.
Robneal
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Re: Burnt Pig - 356 Pre a Build Thread

Post by Robneal »

Photos not working again from FLKR even though I have a pro account, any idea how to fix this???
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Re: Burnt Pig - 356 Pre a Build Thread

Post by Lightweight_911 »

From your main 'Photostream' page on Flickr you need to click on the image you want to post then select the image size (I usually choose 'Medium' 800 x 600).

Copy the image address & paste it between img tags in your DDK post.

Eg

Image
Andy

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- subtracting weight makes you faster everywhere”
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Re: Burnt Pig - 356 Pre a Build Thread

Post by sladey »

If you go to quote Andy’s post you will see the syntax used to display them correctly in his post
The simple things you see are all complicated
I look pretty young but I'm just backdated yeah
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Re: Burnt Pig - 356 Pre a Build Thread

Post by AccidentalGenius »

Great update Rob, thanks for that. I hope to start to prep and check mine for IVA over the summer also... We must keep in touch during this process!!!
Pre-a 356 Coupe (Speedster Clinic Replica)
Robneal
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Re: Burnt Pig - 356 Pre a Build Thread

Post by Robneal »

Right, Fixed the photo posting and they are now working.....so look back to previous post and the images should now be there...

Stuart the Electrician came over on Saturday and I made a long list of additional Electrical bits I need to source, so Sunday night spent an hour or so sourcing all the other bits I need, mostly from Car Builder Solutions who I think are my favourite supplier, as they always deliver next day and are so helpful if you have any issues. Most of the parts were additional switches, relays and battery wiring.

Also spent an indulgent day on Saturday whilst my wife was out actually working on the car, and I had forgotten how much I enjoy it.... A few things ticked off the list of things to do and a few more added...

Make Bracket & fit Temporary Rear Fog / Reversing Light
2. Fit interior Light
3. Fit Electric Window switches WIll actually use toggle switches with guards mounted to a small panel that I will make to fit in the inner door as they look quite cool
Image0033353_stainless-steel-toggle-switch-guard by Rob Neal, on Flickr
4. Fit Door Courtesy Switches Complete
5. Re-Fit door Frames as need to move back by about 10mm
6. Fit strengthening panel to inner door skin as the door inner is very flexible and when Speedster Clinic tried to fit the internal door handle, the fibreglass is really not sturdy enough to support the operation of the handle - Speedster Clinic are developing these panels now as they see that this will be required on all Coupe Cars.
7. Plumb in Oil Cooler and Oil Cooler Fan switch
8. Fit Fresh air intake to heater at the front of the car
9. Fit Fuse board and Relay board ready for wiring.
10. Mount Emerald ECU
11. Mount indicator stalk
11. Re-build dashboard with all clocks and Switches in it - Complete, had to add 2 more switches to the dash for front and rear heated screens, but it balances it up nicely now
12. Make and Fit engine side trim
13. Sort throttle cable operation
14. Adjust clutch
15. Build bespoke wiring loom for car - I have found a local guy, Stuart that builds wiring looms and undertakes wiring for Harry Harpic's air-cooled specialist in Southend and he is going to to build the loom specific to my car and then bind it all. The wiring specification I have lists all of the components and also makes provision for some items I may well add at a later stage.
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Re: Burnt Pig - 356 Pre a Build Thread

Post by Robneal »

OK So lots of progress since the car came home partly helped by the fact I was made redundant and between looking for a new job then there has been some time to spend on the car...so an update to my list and some new photos....

1. Make Bracket & fit Temporary Rear Fog / Reversing Light - Complete - just made a simple bracket to fit on to the Number plate mount and this should be largely covered up by the number plate when it is fitted so the light fits flush with the bottom of the number plate. It is made out of 3mm sheet Aluminium, somay need to have some edging added to make it IVA compliant, but will do this as part of the final IVA pre check

[url=https://flic.kr/p/2hcQy9Z]Image
2. Fit interior Light - Still to do
3. Fit Electric Window switches Complete, made a small panel in the drivers door aperture and it looks quite cool, and is out of the way and is IVA compliant, the panel needs a bit of work to make all the corners even but it will do for now

[url=https://flic.kr/p/2h73mwX]Image

4. Fit Door Courtesy Switches Complete, have added photo now and also added some door conduits to allow the Electric window wires to be neatly and securely routed into the door

[url=https://flic.kr/p/2h8dfJU]Image

[url=https://flic.kr/p/2h6PQS1]Image

5. Re-Fit door Frames as need to move back by about 10mm Not Started
6. Fit strengthening panel to inner door skin as the door inner is very flexible and when Speedster Clinic tried to fit the internal door handle, the fibreglass is really not sturdy enough to support the operation of the handle - Speedster Clinic are developing these panels now as they see that this will be required on all Coupe Cars. Still waiting for laser cut panels from Speedster Clinic
7. Plumb in Oil Cooler and Oil Cooler Fan switch - Complete, this required quite a bit of work to make the brackets and get the hoses to be in a suitable position. I found this picture on-line of a speedster with an oil cooler kit, so took this as inspiration, and used this as inspiration to make my own installation

[url=https://flic.kr/p/2hcQMhA]Image

There is not a lot of space under the rear wing, and I didnt want the cooler to hang down to low so it would be venerable to stones and other road debris... so here are some photos o the various stages of development and the final installation, just needs the wiring to be completed now which should happen this week


[url=https://flic.kr/p/2h8deDc]Image

[url=https://flic.kr/p/2h8aDmQ]Image

[url=https://flic.kr/p/2h8aDpR]Image

[url=https://flic.kr/p/2hcQSDJ]Image

[url=https://flic.kr/p/2hcQTeG]Image

[url=https://flic.kr/p/2hcNkam]Image

[url=https://flic.kr/p/2hcQ6tT]Image

8. Fit Fresh air intake to heater at the front of the car Parts Ordered to complete the Eberspacher heater installation, but just waiting for them to turn up at the moment, will update next time on this
9. Fit Fuse board and Relay board ready for wiring.
10. Mount Emerald ECU Complete

[url=https://flic.kr/p/2hcSaM8]Image

11. Mount indicator stalk - See Wiring
11. Re-build dashboard with all clocks and Switches in it - Complete, had to add 2 more switches to the dash for front and rear heated screens, but it balances it up nicely now
12. Make and Fit engine side trim Got patterns from Rich Maxwell (Thanks) so just need to transfer these to Aluminium sheet and secure them
13. Sort throttle cable operation Have had a look at this and it is not straight forwards, as the Throttle linkage is behind the Fan shroud and difficult to get at without taking the fan shroud off, but I think I am going to try to connect it up and see if it works first without taking it all to pieces, another update of this next time
14. Adjust clutch Complete
15. Build bespoke wiring loom for car - I have found a local guy, Stuart that builds wiring looms and undertakes wiring for Harry Harpic's air-cooled specialist in Southend and he is going to to build the loom specific to my car and then bind it all. The wiring specification I have lists all of the components and also makes provision for some items I may well add at a later stage.Work in Progress but overall probably about 70% of the way through....I am really pleased with the work Stuart is doing on the car as he does everything the way I want it and has suggested things that will make the wiring better. It is not cheap going the bespoke loom route, but i will have a 100% right for my car loom that should be reliable and not be an area that needs constant attention. A few pictures of work in progress

[url=https://flic.kr/p/2h6Uxgi]Image

[url=https://flic.kr/p/2h6PRtG]Image

[url=https://flic.kr/p/2h6Sqch]Image

[url=https://flic.kr/p/2h6RG9o]Image

[url=https://flic.kr/p/2h6TPdV]Image

[url=https://flic.kr/p/2h6S27f]Image

[url=https://flic.kr/p/2h6ZN9W]Image

[url=https://flic.kr/p/2h8cuLc]Image

[url=https://flic.kr/p/2h8dfeL]Image

[url=https://flic.kr/p/2h8cvkP]Image

[url=https://flic.kr/p/2hcQ6x5]Image

[url=https://flic.kr/p/2hcQ6HF]Image

[url=https://flic.kr/p/2hcQW63]Image

[url=https://flic.kr/p/2hcQ6MZ]Image

[url=https://flic.kr/p/2hcQ6Pc]Image

[url=https://flic.kr/p/2hcNo7i]Image

[url=https://flic.kr/p/2hcQ6PY]Image

16. Fit Fuel pipes and fuel regulator - Work in progress here but I have completed the engine bay pipework, and Speedster Clinic had done the pipework at the front to link up the fuel tank to the hard lines that run through the inside of the car. Still need to fit an in-line fuel filter and sort the flexibles that link to the engine bay in the rear

[url=https://flic.kr/p/2hcQsP5]Image

[url=https://flic.kr/p/2hcT12a]Image
greg356a
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Re: Burnt Pig - 356 Pre a Build Thread

Post by greg356a »

Fantastic amount of work completed, really progressing! Great to see the updates
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Re: Burnt Pig - 356 Pre a Build Thread

Post by Bootsy »

Yes superb progress, thanks for keeping us updated
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Re: Burnt Pig - 356 Pre a Build Thread

Post by Robneal »

Right, have a much bigger list now of all of the things I need to do, but its a bit messy on a Blog, so I will just list the progress I have made.

Wiring
The Wiring is nearly done now and Stuart of SR auto electrics has done a great job of making and installing a bespoke loom, but it has taken some time...14 days so far and still the final switch on and full test to do. Not really many changes from my original spec, but I have got plugs on most of the removable elements so I can get things out easily if I need to. For Example the whole Dash is linked on 4 plugs and this means if the dash needs to come out then it is a relatively easy job to remove it with all of the wiring in tact. Heater Blower, Eberspacher Controller, Indicator Stalk etc. all have separate plugs.

Image20190926_152709

Image20190920_152938

Image20190914_111139

Image20190926_152859

Accelerator
Fitting the accelerator cable was quite tricky as the rear fibreglass tub actually protrudes below the level of the front tin and therefore the flexible accelerator tube that enters into the engine bay was at a very steep angle and would have made cable operation impossible, so I had to remove the breather and then very carefully with a rasp drill grind away the fibreglass so I could get the flexi Accelerator tube at the correct angle. I also had to buy a part from Vintage speed that fits from the rear of the Engine front tin to allow the cable to sit properly with the flexible tube and the front tin. It was then very tricky to get the cable linked into the Vintage Speed Best Linkage and adjusted to make throttle operation work. There still seems to be very little pedal travel, but there is full operation on the throttle so will wait and see how it drives....

Image1030143288

Image20190911_160653_001

Image20190911_160652

Image20190926_152944_001

Radio / Stereo
I Have decided to fit a Radio Stereo to the car from the outset with modern hands free capabilities as I am so used to these from my daily driver. I ended up going for a Pure Highway 600 head unit that supports DAB and FM radio and Bluetooth and hands free dialing from your connected phone. I have also bought a 2 Channel Amp and will just fit front speakers in the footwell, but have yet to decide on which ones I want..


Dash Face plate
The central panel in the middle of the dash I have decided will hide any modern electronics and I am looking to install behind a false faceplate a DAB radio head, a USB socket and the MAP switch to allow me to change the maps on the car via a switch on the dashboard, I may also mount the Eberspacher heater controller there to if there is room. I have made a carbon panel to fit in the space and hide the modern electronics, and have started to make the recessed pod from aluminium that I have now fibreglassed to the dash and then as you can se in the photo I am just filling the gps that are left with filler which I will sand down.

Image20190926_152715

Image20190926_152810

Image20190926_152855

Bonnet Stay
Although Speedster Clinic had fitted a bonnet stay, there were no Grommets in the body or the bonnet so it felt a bit loose and rattly, I have now added grommets at both ends and have also added some clips so the stay will not flap around under the bonnet when not in use.

Image20190926_153056

Heater
I have decided that I am only going to fit the heater blower before the IVA test and leave out the Eberspacher heater at this stage as it requires installation certification for the test and the only local certified installer does not provide a mobile service; so for the IVA test the blower will just blow fresh air. I have completed the installation of the blower which takes a Clayton heater I picked up on EBay and I have fitted a 3 inch fresh air duct from the inside of the drivers inner wing into the heater blower. I have then used the outlets at the side of the clayton heater to link to the top of the dash vents and also the eyeball vents at the end of the dash. The second set of vents will connect up to the original Clayton heater outlets, but as they have a lot of sharp edges, will leave fitting till after IVA.

I also found out that the eberspacher heater model I have does not have a water circulation pump internally so I have had to buy an external one from Webasto. For others that are thinking of a water heater for a build then I would recommend the Webasto thermo top petrol heater as they seem much cheaper second hand and also they come with a circulation pump as part of the unit that is operated by the heater controller, as I am going to heave to wire in mine to run all the time the heater is running, but unlikely to be an issue.

Image20190926_153120

Image20190926_153130

Refit of Brake master Cylinder Reservoirs
Where the brake master cylinders had been fitted the holes through the fibreglass into the under the bonnet area were way bigger than they needed to be and would have let in unwanted water and road dirt so I have made an aluminium plate with grommets in it to ensure that the reservoir pipes are sealed and no unwanted water can get under the bonnet. I also added a separate grommet and hole for the plumbed in fire extinguisher pipe.

Image20190926_153107

Big ticket items next on my list to tackle are:
Doors - Still waiting for the inner strengthen plates from Speedster Clinic
Electrics Testing - Probably will happen this week
Kick Panels - make some kick panels to house speakers and to ensure the sharp edges are hidden

Still lots of minor jobs to do like tilt the seats, but as I will be off work for the next couple of weeks, i really hope to be getting to the stage where the car is IVA ready in the next month or so...
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Fuchs915
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Re: Burnt Pig - 356 Pre a Build Thread

Post by Fuchs915 »

Great work Rob, as I am getting back to mine, this is proving very helpful. Plenty of food for thought as I ponder all those seemingly small but key questions about my build - dash layout, heat, pop outs or not, what can/can't be done for IVA, etc..

Importantly, good luck with the job hunt.

All the best

Kevin
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Re: Burnt Pig - 356 Pre a Build Thread

Post by AccidentalGenius »

Great to see your progress Rob, its looking great!

I am, i think, a couple of months behind you but it would be great if we can get both cars on the road next spring!

I too bought a carbon fibre panel for my centre dash but have mounted 3 gauges in it. I like the idea of hiding some tech there also, or at least using that space for removable tech. I am currently thinking about mounting an ipad pro over the entire centre section using a magnetic mounting system, and using this as the source for Spotify and Maps (ie satnav). I am not sure how much you are in to your music but i have gone for Focal speakers and amps as they produce a gorgeous sound (to me at least). For this CarAudioSecurity.com was a good price at the time. If you get a 'digital' or Class D amplifier it should draw less power from the battery, which is helpful!

Keep up the good work!
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Re: Burnt Pig - 356 Pre a Build Thread

Post by Robneal »

Hi Adam,
Would be great to see a picture of your dash as I'm not sure I've seen one yet, and the three gauges sounds kind of neat. I have mounted my 3 gauges underneath in a pod on mine but I guess the centre mount looks balanced, and keeps the dash lines cleaner.

I have also been thinking about the interior and saw these seats that a guy North of Manchester does, he does them as covers or as complete refurb, but would have to get my seats to him, I also think this design would look better on my MX5 Mk 2.5 as the centre panel is a little smaller and not so blingy....

Imageimage1
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Re: Burnt Pig - 356 Pre a Build Thread

Post by AccidentalGenius »

Rob,

This is my dashboard at a point when the 3 dials were still in the template, not the finished thing!

Image

Image

With regards to interior, i have had a brief conversation with Kens Customs and would hope that i can get them to do a full interior fit out including seats, door cards and carpets etc. I am in two minds about upholstering the centre dash (behind the 3 dials) to match the seats...
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Re: Burnt Pig - 356 Pre a Build Thread

Post by Robneal »

Quick Update on electrics, the switch-on has happened and bar a few minor problems pretty much everything worked first time. Here are the problems most of which have been highlighted by the electrics working...

Fuel Gauge Mismatch with Sender - installed a gauge matcher from car Builder Solutions and after finally deciphering the instructions that were not all that clear I now have successfully matched the gauge to the sender unit. Might have to do the same with the Oil temperature and Oil Pressure too once I start the engine, but now I know how to do it, it shouldn't take too long, but will need manual gages to to set them up to a reference point.

Vacuum Pump to run servo - Firstly there was no vacuum, but once we tested the pump, just had the Pos and Neg round the wrong way and as non return valve installed no air was coming out to determine this, switched them over and the vacuum pump now works and switches off with the switch, but I am loosing vacuum somewhere, so kicks in every 5-10 seconds to replenish the vacuum. Need to know where it is leaking from so will use Fairy Liquid and a pump tomorrow to hopefully identify where the vacuum is escaping from. Hopefully this should be fairly easy to fix, my guess is hose or a non return valve, but investigations should tell.

Indicator Switch not working - Simply had the wiring round the wrong way as terminals were not as expected on the Beetle Oval Indicator Stalk, easily rectified by switching the wiring round.

ECU - Just turned the engine over to see if I was getting a signal from the crank trigger which apparently is the first thing to check when you are starting the engine, and although I could see an output from the crank sensor, the LED on the side of the Emerald K3 ECU that should flash alternate Red / Green was not indicating the ECU was detecting it. Need to check the gap between the trigger wheel and the sensor as it looks too big and will then try again.

Image20191003_182052

More updates soon as still not started a new job yet.
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