Intercom fitted and Shift Light Installed on Dash

Sat/Sun 21/22 Aug 2010 - Work time = 3hr ... Build Time to IVA = 252hrs ... Post IVA Build Time = 16hrs

The Intercom set arrived this week so I fabricated a simple bracket to secure the amplifier to the transmission tunnel between the seats.  Sprayed it all up to look nice too!  I had already spliced in the power supply to this location when I installed the loom so it was an easy installation. 
The intercom is a Terratrip Professional Model with Practice headsets that have noise cancelling microphones (to avoid too much background wind noise).  I've used this model previously in the Cobra I had and it worked really well.

Next job was to install a gear shift light.  The ECU loom came prefitted with a shift light and the ECU is mapped so that this illuminates when the ignition is initially turned on (goes out when engine starts) and when the RPM reaches 6,400.  This is 400rpm before the rev limiter comes in at 6,800rpm. The wiring for this indicator light was very short so as part of the installation I'd left it tucked in with the loom wiring near the ECU so the light wasn't visible.

I decided to relocate the indicator light to the dash.  A simple job of extending the wires and moving the existing Ignition (Alternator) Light.  Here's the finished view with the Shift Light under the Indicator Lights behind the Steering Wheel and the Ignition Light to the left of the Hand Brake light.

Need to run-in the car for a few more miles before I can test it !

Managed to have a couple of drives over the weekend (about 90miles in total)  It was raining on Sunday ... the first time I'd driven in the rain.  The front mud flaps seemed to work well.  Somewhat surprisingly the wipers worked well too and provided I kept moving I didn't get too wet in the cockpit.  Oh and the coolant temperature was much better too after the thermostat change ... indicating around 85-90 degrees on the temp gauge with the fan only cutting in when I was stationery for a while. 

Whilst I was out I managed to calibrate the Brantz Meter to read in kilometres.  It seems to be working OK at high speeds but is not incrementing at slow speeds (below about 25mph).  Further investigation required to fix this as it's vital it's reading accurately at all times otherwise we will quickly get lost on Corsica!

Total miles covered so far equals about 480 !

More Rally Preparation ... boot rack

Sun 15th Aug 2010 - Work time = 3hr ... Build Time to IVA = 252hrs ... Post IVA Build Time = 13hrs

As mentioned previously the boot in a Westfield does not resemble Doctor Who's Tardis and is definitely not bigger on the inside.  This presents a challenge for luggage space for 2 larger than life adults, Paul and myself (kindly referred to as "Team Lardy" by Sandra!).  My solution (and our only option unless we tow a trailer!) is to secure some rucksacks to the rollbar. 
To do this I needed to have some sort of platform to raise the rucksacks off the bodywork to avoid any damage to the gel coat and also allow access to the boot.  My design solution ... a boot rack.  
With a few pipe clamps (purchased from eBay of course) and some square aluminium tube from B&Q, some nuts and bolts and a lot of head scratching and heh presto the Todman Westfield boot rack ... an engineering marvel.

New Thermostat

Sun 15th Aug 2010 - Work time = 1hr ... Build Time to IVA = 252hrs ... Post IVA Build Time = 10hrs

Since I had the car on the road I was a little concerned that it was running a little hot.  Even travelling along at 50+mph the fan would need to cut in fairly regularly to keep the coolant temp down.  A quick call to Mark at Westfield confirmed what I was thinking ... the thermostat was set too high.  The standard fitment is a 92/102 stat ... starts opening at 92 degrees and is fully open at 102 degrees.  According to my dash temp gauge the fan was cutting in about 95 degrees so there wasn't much time for the stat to open and allow flow through the radiator.  Mark suggested at 82 degree stat ... as fitted to their race cars.  Not sure why this wasn't suggested when I collected the car? .. would have made things a little easier!  After a bit of searching on the WSCC forum I tracked down the correct 82 degree stat (as fitted to a Rover 416 !).  A quick trip to Halfrauds for the new stat and some anti freeze.  Refitted, refiled and tested up to operating temperature with no leaks.  Will have to see what it's like on the next run.

Rally Preparation ... Brantz Meter

Tue 10th Aug 2010 - Work time = 1.5hrs ... Build Time to IVA = 252hrs ... Post IVA Build Time = 9hrs

Time to start preparation for the Corsica Rally in October.  First thing to be fitted was the Brantz Meter.  The Brantz Meter is an accurate trip meter, showing distance and average speed.  Once calibrated it will read distances in 100ths of a kilometre.  Essential for the rally navigation which will be tulip map directions and distances (no road names or numbers or destinations!).
I had spliced in a wire into the loom to take the pulse feed from the speedo sensor and I had also planned for the power supply.  So it was a fairly easy fitment ... except once I connected it up it wasn't registering any pulse from the speedo sensor!  I had connected to the wrong speedo connection ... doh!  I had to remove the dash and make the correct connection which then registered the pulse.  A 30 minute job turned into a 90 minute one. 
Here is the Brantz Meter fitted ... just need to calibrate it now.

Carbon Fibre Rear Arch Protectors & Front Mud Flaps

Sun 8th Aug 2010 - Work time = 4hrs ... Build Time to IVA = 252hrs ... Post IVA Build Time = 7.5hrs
Finally got round to fitting my Father's Day present ... some rather splendid wheel arch protectors in carbon fibre!
The suppliers (CarbonMods) suggested I fit them with just some silicone sealant but the fit on the inside edge wasn't too good so I ordered some black rivets off eBay to secure the inside edge against the bodywork.

I then turned my attention to making some mudflaps for the front wheels.  I had already purchased some 3mm Rally Mudflap material from eBay and I had some big head fasteners left over from fitting the arches.  I fibre glassed the new big heads in the same as before and bolted the mud flap to them. 

The more observant amongst you will also see that the side indicators that were previously fitted to the wheel arches are no longer there.  These were fitted as part of the IVA requirement.  Miraculously new ones have now appeared in the more traditional position on the side of the car.  This must have been completed by the "garage pixies" as it would not be right and proper for me to move them from the position required by the IVA !  ;-)