Coming along nicely now. Glad that you got over the screw hole problem.

Alec

This is looking brilliant Gray!

Regards,
Phil W.

In Pack 13 we start by fitting the radiator pipes. No dramas here, with everything going together as it should. The details and Lambda probe plugs followedf in the same vein.

Where i do encounter an issue is with the two limit switches, which attach to the frame. It's a case of 'square peg and round hole' - literally! The hole on the frame would need to have a slot created for the switch to fit, so instead i shaved the end of the switch off and superglued it in place! Not ideal but will do the job (and no-one will be any the wiser once bodywork is fitted). The failead slotted into place easy enough, but the cap need a little glue to keep it in place on the frame.

Hi Gray,

Coming along a treat now, as you say some instructions and photos are a bit vague and I have found out to my cost that it pays to read the instructions at least three times before commencing assembly.

I love your support frame, it must be a great help with this heavy lump.

Alec

Here we assemble Pack 14, which starts with Stage 51, more details and Lambda probes. First, though we need to attach another fairlead to the right side of the frame, in front of the last fairlead, and thread the clutch cable through it.

We then attach the plate that came with this issue to the frame, below the fairleads, locating the pins into their respective holes. Two caps are then fitted into the holes in the frame to cover the screwheads visible in the frame.

The two Lambda probes slide into the two tubes and are attached to the Lambda sensors and fitted to the bracket using the locating pins in the probes.

In Stage 53 we assemble the right footrest. First, we attach the hydraulic pump assembly to the footplate. Its just a simple push-fit. The upper plate fits in the same manner.

The right footpeg slides onto the dowel on the assembly. It will only go one way because of flat spot on the dowel. The rear brake peddle slots in to hole below it.

Fitting this assembly to the frame caused a slight headache, as it wouldn't sit right due to one of the screws protruding from the blue exhaust bracket mount. After a bit of fettling, i got it to sit where it should, but the lower screw wouldn't tighten fully home, and i didn't want to force it too much. It's holding, but not as it should.

Hi Gray,

My word, you have been busy. Great build diary.

Alec

Pack 15 starts with Gear lever assembly.
Retrieving the footpeg bracket and left footpeg from Stage 54, the footpeg bracket inserts into the open end of the footpeg. You can't get the orientation wrong as the peg has a half-moon shape inside. Aligning the flat spot, it just slides on.

The gear lever slots into the hole below where the footpeg was inserted, and held in place with a screw. Don't over-tighten as the lever need to move fairly freely.
Fitting the linkage comes next. The ind with the pin goes towards the hole, and is again held in place with a screw.

Attach the top plate by locating the two pins on the underside. The assembly is then screwed to the frame. Taking the tube that we fitted in Stage 49, this goes onto the pin on the gear linkage. The linkage is then attached selector arm.

Stage 57: The Subframe.
First job is to attach the fairlead. Again, you cant get it the wrong way up, as one of the pins is larger than the other.

The longer of the two tubes slides onto the pin on the blue end of the connector.
The shorter piece slides onto the other end. I found i had to use a toothpick to widen the tubes slightly to make them fit easier. I also had to shorten the smaller tube, as it was about 10mm too long! bending the shorter tube, it fits onto the pin on the hydraulic assembly. It looks a bit floppy as there is nowhere to mount the connector, other than pushing the tube through the fairlead fitted earlier.

Good progress continues, well done.

Alec