March 2004 Update

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Not as much progress this past month as hoped due to problems with my road car. I had to replace the fuel tank, rebuild the brakes and replace the exhaust front pipes. Now that is done we can get on with the Locost!

My main aim at present is to finalise all the welding on the chassis so that I can strip it down one last time and prepare and paint it. Despite a fairly dry garage which is aired regularly with my little fan heater, the chassis is developing some surface rust and I am keen to get some paint on it before it starts to pit. Once the chassis is painted I can begin the final assembly along with all the panelling and fibreglass work.

I have made a long list (98 points) of work which needs to be done, I'll maybe categorise the list and display it here later but for now I'm too busy trying to reduce it a bit. I listed all the work items into a dictaphone and then wrote it up later. A dictaphone is a very handy little tool to use for this sort of thing and I'd recommend it as an easy way of recording information (measurements etc) when you are in the garage which can then be referred to later without forgetting anything.

Anyway, recent progress includes the lower four seat belt anchorages, completion of the steering rack mountings and some progress with the design and assembly of my pedal box. I have also now sourced a new set of Cobra seat runners to use on the passenger's side. The rollbar components are also now fully welded

Here are some photo's of the pedal box from various angles.

Sourcing Braking Parts & Recon Rear Brakes

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Quick update:

Got some bits from Brakes International including: (All prices are ex vat)

•2 Caliper service kits for the Sierra rear calipers (P/N BCK4303 @ £ 8.05ea)

•1 Caliper piston (P/N BCP4308 @ £ 14.37ea) - The other piston was virtually new.

•1 Clutch slave cylinder for Rover SD1 (P/N CSC3020 @ £ 19.30ea)

•1 Fiat Uno rear brake adjustable pressure regulator (P/N HRV1013 @ £ 13.95ea

Using some of the above bits I have rebuilt my rear calipers after cleaning the bare casings up using the electrolysis method of rust removal as described elsewhere on this site. I then painted them with smootherite silver paint.

I'm really pleased with the outcome and it has worked out much much cheaper than using reconditioned calipers. Recon calipers would have cost around £ 41 + £ 25 (surcharge) + vat (£ 155 for pair) as opposed to £ 36 for the pair as above.

These calipers are not the easiest to service due to the rather inaccessible handbrake mechanism which ideally requires a special Ford spring compressor. However, with a bit on ingenuity it can be done and here is how I did it:

Follow the procedure in the Haynes manual for the general disassembly and remove the piston as directed. The mechanism inside the piston must be transferred to the new piston if you are fitting one so don't throw it away just yet! You can strip all the rubber seals away from the caliper and remove the handbrake lever spring. Now clamp the caliper in a vice at a comfortable height and with the exposed bore facing upwards. If you look inside you will see a long threaded rod with a spring and spring housing around it. This spring must be compressed before you can release the retaining circlip and this is where the fun and games begin!

What you need is a very long slender pair of circlip pliers and a nice compact spring compressor. I found that I could use the Sykes Pickavant piston windback tool with an 12mm socket between the end of the windback tool and the handbrake spring cover. I could then wedge the edge of the windback tool under the caliper body and hold it in place with a couple of tiewraps before cranking it down on the spring cover. You can then use the slim circlip pliers to release the circlips before unwinding the compressor and removing the parts.You can buy a small kit of suitable circlip pliers from Screwfix direct for just £ 7.99. The part number is 24554-53 and it can be found here.

Here's a photo of these circlip pliers.

I also got some bits from Rimmer Brothers including a clutch master cylinder repair kit, thermostat gasket, propshaft nuts and bolts and a few other bits and bobs.

Finally, some progress has been made on the chassis and the drivers seat has been fully mounted and welded into position. I have ordered another set of seat mounting rails for the passenger seat as this makes mounting the seats much easier. This should arrive in the next couple of weeks.

Another update at the weekend with a bit of luck!