[Project] The Rattlebox

[davenport 51]

Yeah... I know its a massive ballache but imo (and from seeing cars such as the Gallacher focus/cosworth and the RCM gobstopper2) the only way to do it properly is fully build the car making changes as you go.. THEN strip it down and paint it.. then do a final assembly..

Edited May 7, 2014 by davenport

[davenport 51]

needed to mount the relays up near the centre console to aid the wiring so took the opportunity to make an OTT bracket...

 

started off with a simple 3 sided tray:

 

 

 

attacked it with a thin disc/holesaw/file.. stitched some M6 nuts on the back and hit it with some temporary black aerosol:

 

 

 

 

which fits all up like so:

 

 

 

and mounts up here:

 

 

 

 

got a new cat to fit on the 307 saturday so will hopefully get the shafts length corrected and fired back down to cornwall.... again.... lmao...

[adman 5]

Awesome build, Your engineering skills and attention to detail is outstanding. Keep up the good work

[davenport 51]

Haha

 

Thank you.. my mate on the bench beside me at work did however point self tappers and cableties would be easier..

[nick205 12 5 Cars]

Haha

 

Thank you.. my mate on the bench beside me at work did however point self tappers and cableties would be easier..

 

They might be cheaper, quicker and easier, but they would look amateur. Especially given the quality of the rest of the build!

[koti 7]

Just read the thread from start to finish...absolutely awesome, can't wait to see it finished now!

[davenport 51]

Thank you... thanks everyone for the kind words..

 

Would love to be able to progress things quicker but simply can't.. lol

[davenport 51]

hello all..... been a bit quiet hey....

so errr....

i`ll keep this brief as tbh its not much to tell....

Pete over KAsensors sorted me out with 1 of his trick little air temp sensors, and Specialist Components have been sent the info to modify the ecu to deal with that...

Ive been working away over in Port Talbot on and off these past few months so made a detour to Dannys on the return trip while i had the van and collected my spit off him, that was then thrown into the powder coater at work and now wears a shiny coat of red!

after a bit (actaully a LOT!) of f***ing around Dave @ Satchells did the buisness and shortened a couple of shafts for me, these were then built up with new CVs both ends and new boots:

wheel speed trigger was refitted on assembly and i just need to make a new bracket to mount the hall effect (possibly off the 2 M7 Jbolts that hold the intermediate bearing in the housing):

and.... errrrrrrrrr that really is about it

[davenport 51]

Hello...

 

In between his day job/family holiday Seans managed to keep things progressing.. had a small issue of a deutsch crimping tool going missing in the post!! ££££££££!! But thats been sorted and hes sent over a few more piccies bless him..

 

 

 

 

 

 

I cannot begin to say how happy I am with it.. its everything I imagined and wanted.. cannot fault his service at all..

[davenport 51]

hi folks.. how ya`ll doin???

started laying them out in the car and figured i needed a little bracket to mount the Souraiu AS connector:

fiddly little bugger as those bolts are M3x5mm

anyhow, got that made and fitted up:

Fuel harness all layed in:

Seans been over to measure up the final bits (engine harness and the 2 small bits that will power the front lights) he`s also took the dash complete to do that:

as you can see the fuel lines need pinning down, bit of an issue there, my cheap ebay nutsert tool decided to s*it itself after 1.. ONE!!! nutsert, i wasn`t expecting it to provide a lifetime of service and be handed over to Jenson on my deathbed but i did expect a bit more than 1 poxy rivnut...

emails have been sent to the seller but i doubt i`ll get a refund.. probably easiest just to wrap it up in 1 of Jensons dirty nappies and post it back to them..

problem sorted with the rivnuts...

i borrowed the works gun:

and just incase i had access issues in tight spaces i made up a quick ghetto tool:

a few more hours today and i ticked off a couple of jobs that have been niggling me for a while:

4th engine mount:

painted and fitted:

and also the wheel speed sensor bracket:

fitted up:

also (if you follow him on FB you`ll have seen this but another little bit of loom is just about done for the passenger side front lights:

there will be another piece for the drivers side with an aditional spur for the horns, both of these pass thru the Apost under the wing and poke back out near each headlight so all out of sight

More wires...

2 small sections- these connect under the dash and pass thru the Apost area up into the inner wing cavity above the liner to feed the side repeater/front repeater/headlight.. the drivers side piece also has provision for the horns located just above the bumper vent..

and the brake pressure switchgetting its 'gucci gucci' souraiu AS connecter fitted:

been throwing in those 4 sections today,

started off with the rear light section..

which plugged into the chassis harness up near the washer bottle:

and ran around the back of the car to feed the 2 rear lights and the 2 numberplate lights:

nothing however is that easy and to get the feeds thru the shell to inside the rear bumper i had to open out the small square holes to 20mm dia, find a suitable grommet, unpin the connector, thread the grommet on and then reassemble the terminal:

next job, fit in the Tpiece with the brake pressure switch which will activate the brake lights:

so far so good, the lengths on the wires were all pretty good..

to do the front light runs the wings were whipped off along with the wheels..

passenger side:

pretty hard for the phones camera to pick up but the pattern from the twisted raychem44 wire looks mega, all uniform and even:

the big ass hole in the passenger inner wing where the std loom passes thru will be welded up then a smaller dia 30mm hole put in for the grommet Sean fitted....

drivers side (30mm hole cut and grommet fitted)

lengths again all looked good, but this side also had the feeds for the horns:

wings back on, you can just about make out the deutsch DT connectors cable tied to the dash bar of the cage, theres 1 each side for the front light looms and another on the passenger side that runs down the car, these will all plug into the dash loom when that comes back...

Edited October 26, 2014 by davenport

[allye 530 3 Cars]

Looks s*it and bodged!

 

Amazing work as usual, one of the longest projects going!?

[stu8v 68 1 Cars]

With all the work you have put in why would you not box in all the fuel system?

 

It always concerns me to see it all in the cabin.

[davenport 51]

Looks s*it and bodged!

 

Amazing work as usual, one of the longest projects going!?

 

haha probably.. bit of a standing joke among some.. what can i say.. i do stuff when i have funds and time... these things rarely happen individually let alone simultaneously..

 

 

With all the work you have put in why would you not box in all the fuel system?

 

It always concerns me to see it all in the cabin.

 

if i ever decide to start doing track days i`ll make a smaller tank (25 or 30 litres max) then squeeze everything else within that steel box and bang a lid on.. for now, meh.. it`ll be fine

[rallyeash 155]

Awsome.

[S@m 156]

One of my favourite projects of the last few years - Awesome work.

[calvinhorse 870]

Great work as ever

 

 

Have you priced a air operated 'rivnut' gun? The one you borrowed is close to £1500! Mental

[davenport 51]

Thanks to all for the kind words..

 

Yeah, the nutsert gun is a bit ££££ tbh the inserts in the inner wings i did with my homemade ghetto tool which was fine.. that said at work we fit hundreds of stainless M8 ones and i wouldn't fancy doing that with it..

[HERMAN 33]

Great work.

Were did you get your harness idents printed?

[davenport 51]

All the loom work was done by sean @ bespoke wiring solutions

 

He has the printer and various sizes of yellow shrink

[davenport 51]

the box of exhausts bits has been piling up over the past few weeks...

 

so, armed with a few sketchy measurements i set about laying a few things out:

 

 

 

a 2.25" bend was cut up to match that shape, and a piece of 2.5" tube was shrunk down to match up with it:

 

 

 

that was then thrown together with the Vband assembly Mike Edwards was kind enough to supply:

 

 

 

and along with some more bits all tacked up into something resembling what i need:

 

 

 

from here i need to make sure everything is right sizewise then strip it down, purge everything and tig it all up..

 

i`m still not 100% sure on the tailpipe.. i really like the idea of the downswept as i`ve used in the mockup.. if not it`ll be a plain straight piece of tube..

[stu8v 68 1 Cars]

I went downswept on mine, i believe it helps with noise tests too to some degree.

[davenport 51]

Not really an issue for me as i doubt it will see a track.. this is a pure aesthetics choice lol

[Kane 34]

Brilliant thread! Just finished reading from the start, your fabrication work is exceptional. Just out of interest what is it that you do for a living?

[davenport 51]

Thank you for the praise, very kind of you...

 

primarily i'm a welder/fabricator (mostly sheet work) but in the past have worked as a CAD draughtsman.. a machinist and truck fitter..

[sparx10james 0 1 Cars]

reading this makes me want to tear my car apart and start over.....amazing work lad fair play