Journal of Updates

December 17th, 2005 - Hard to believe a year has passed.  A number of changes have occurred since the last update.  The car is road legal.  The seats have been mounted on angled platforms, fixed against the rear firewall for maximum leg room.  The steering column has been raised 2" and a quick release hub added.  This allows for more knee room and a more comfortable driving position as the wheel is closer to you.  I'm not happy with the look of the front tires.  The profile is tool low.  I'm considering fabricating a new set of upper and lower arms to move the wheels forward in the wheel well.  I may try a set of 195/60 tires before I proceed.  All in all the car has far exceeded my expectations.  It's a blast to drive and turns heads.  Another deal in the works is a 016 gearbox with 3:16 ring and pinion.  The overall drive ratio will be much better and highway cruise should bring the RPMs down.  A prototype is in the garage and I'm waiting for the weather to cooperate so I can swap it in.

December 22, 2004 - A temporary trip permit and a few laps around the neighborhood were the call of the day.  Inspection is still pending and will likely wait until the weather clears.  For all intensive purposes the car is complete and roadworthy.  Two and a half years of building fun.  I learned a lot, was challenged and used all the expletives I know.  This one is a keeper.  Stay tuned for road reports come spring...

November 17, 2004  - Windshield is in and I'm in the way to license the beast.  A few more details to take care of but the first drive is close.  Minor interior details and a nut and bolt check are next.

September 25, 2004 - I've been fiddling with the interior. The firewall is upholstered, and the fresh air intakes installed.  Vents and hoses are in place.  I've ordered a speedometer cable and should be able to install the dash and begin carpeting.  There are a ton of details to complete.  Next up installing the sill thresholds, fastening the lower tank covers, installing seat tracks and belts,  removing the alternator bracket and installing a bolt to allow belt tensioning and swapping the pin drive adapters from side to side as the drive and passenger knock offs tighten in the improper direction.

July 10, 2004 - Paint is done.  The car needs a polishing but final assembly will occur before that happens.  We had our first road rash incident while pulling the car up the driveway.  We have a fairly steep driveway and the front of the nose bottomed on the curb.  Can't see it unless you lye on your back and look up.  Not to worry, this car isn't going to be a trailer queen!  Back to the garage...

July 5, 2004 - Paint is almost done.  Hopefully this week.  1061 was at the track this weekend.

June 25, 2004 - Paint is continuing to progress.  All parts are blocked and ready for color.  Should be all done next week.  Seats are back and look great.

June 17, 2004 - Paint is progressing.  The rockers are painted and ready to go.  Body has color and will be striped and cleared next week.  The seats are also in work.  Superior Auto Trim is skinning them in black leather.  Pictures soon.

May 25, 2004 - The garage is empty.  The 40 has been loaded up and sent off for paint.  Scott Morgan of Scott's Shop will be doing the work.   Prior to getting the car off to paint I installed the CV adapters and Taylor Racing axles.  Packing those CVs with Redline synthetic CV grease is a messy proposition.  While installing the axles I noticed the CV bolt shoulders touched the coil over springs.  I'll replace the bolts with short shoulder hex units when I get the car back.  Talk about packing 10 pounds in a five pound bag!  Pictures of the paint progress and bolt issue will follow.  Another unexpected gotcha occurred when we rolled the car out and into the trailer.  The front tires contact the rocker panels and inner frame.  Evidently the 215/60/15 tires are a bit too large.  I have a set of 205/50/15 tires on hand that should fit the bill.  Anyone need a set of unused Dunlops?  I'll be making a punch list and looking for an upholstery shop to make the seats while the car is out.  More pics in the body section...

April 23, 2004 - Long time no update.  The body is ready to paint.  Red/White is the combo.  Drive axles are on order.  Dave milled up a set of CV adapters so I can use 108mm units inside and out.  Should be under it's own power in a few weeks.

January 1, 2004 - Happy New Year!  18 months into it!  Lost some momentum on the site updates.  The body is blocked out and being fitted with latch mechanisms and gaps are being aligned. I've been troubleshooting a rich running engine and found that my fuel pressure was too high.  Backed it off and we are in business.  I need the CV adapters before I can get axles cut.  I'm close to rolling though and hope to be off to paint in a month or so.  I've updated the pressure regulators to low pressure units from Holley.  I also added a few shifter detail shots here...

August 22, 2003 - OK, OK.  Summer is upon us and vacation and travel have impacted progress.  At least we are having fun.  Here are some pictures from the 2003 Monterey Historics.  This is the first time all surviving J cars have been united.

July 27, 2003 - It's been a while since my last update.  I've been working on blocking the body and getting it ready for paint.  The summer heat has cut down on my hours in the garage.  I've done a nut and bolt check on the chassis and performed an initial alignment.  My CV adapters are in work and axles will be in route next week.  I did video another engine start for kicks.  

July 1, 2003 - Once again time is flying by.  I've been working on reinforcing the idler belt pulley on the front dress as it seemed to flex a bit.  I've tried two belt lengths, one too long, one too short.   The CV adapters are coming along.  It's funny that I haven't taken any pictures lately as most of the major work is complete.  I'm moving on to the body shortly and hope to get the paint process rolling.  Stay tuned as I'll have a real capture of the engine firing later this week!

June 12, 2003 - I've been puttering with the engine and trans mounts.  I found out my tank solenoid valve was wired backwards so the valve was open to the tank with the dead pump.  That explained the lack of fuel!  I posted some pics of the Audi ratios and how to ID the transmission here.  CVs are here and adapters in work.  Hopefully I'll be rolling by the end of the month.

May 24, 2003 - After almost 11 months of work I fired the motor in the chassis.  There were a few minor issues such as a loose clamp on the fuel filler and a loose AN fitting on the filter boss.  All of these were easily fixed.  Click here for a 4 second teaser Quicktime video.    There are still a few kinks to work out such as completely filling the cooling system and adjusting belt tension.  Thanks to Carman for his help.  The shift linkage is also complete.  Next week I should have the CVs in place an axle measurements to Taylor Racing.    

May 20, 2003 - The linkage is complete and all the cooling pipes are in place.  The water neck is being welded this week.  Hopefully I can start this bugger this weekend.  I added some door lock pictures in the interior section.  These are cam locks that came from McMaster-Car.  I spent the last few weeks finishing the dash wiring.  This included installation of the wiper motor, fuel pump switch and a number of other switches.  I also wired up a Derale adjustable fan thermostat.  I have some 108mm CVs for the Audi.  I'm going to mill some adapters for the outers as the flange is designed for a 100mm CV.  The 108mm units should be plenty strong.  Taylor-Racing has been a big help sorting this for best performance.  Once these are done I'll have the axles cut and splined and we should be under power.  

May 6, 2003 - This year is screeching along.  I spent the last few days fitting the plumbing for the surge tank and working on the cooling lines.  Once again, Bob from Bob's Homebrew in the U-district, worked his TIG skills to finish the front cooling lines.  The tuning came from Burns Stainless.  I'm waiting for an AN bung for the return line so I can weld up the coolant water neck and make the final connections for the cooling system.  I have a Derale adjustable thermostat on order for the fans.  Heater plumbing ties to the front tubes.  I've decided to forego A/C for now.  After reading about cockpit greenhouse effect I've added a trick little 100 cfm fan to clear the air.  I also installed the shift linkage cables.  Robust, low friction, push-pull cables from McMaster.  Perhaps overkill, but the price was right!.  I'll make the final connections this weekend.  The final bit is an accelerator pedal.  Linkage will follow soon.

April 30, 2003 - Time stands still with a hand full of small tasks.  The surge tank is in place, oil cooler fastened and plumbed and the dash wired.   We are almost ready for lift-off.  A special thanks to Dave Perry Innovations for the shifter linkage. Tequila is the only accepted form of payment!  Photos don't do justice to the quality of the work!

April 21, 2003 - Time fly's when you are having fun.  There are a ton of details to attend too.  All the mounts are in place.  I've been working on the oil system.  Filter, thermostat, cooler.  Here are the pics...   Next is the shifter, cables and mating connectors.  The cooling tubes are in process.  I have an aluminum setup that I'll weld to the thermostat neck and stainless tubes in the front.  I need to weld some bungs for the heater and fan thermostat in the front tubes.  I've been researching CV joints.  I think Porsche 930 CVs are the way to go.  In a couple of weeks we should have lift off.  Stay tuned.

April 6, 2003 - I spent the last two weekend reinstalling the motor.  Remember the old adage, measure once, cut twice?  I didn't!  It was necessary to move the motor back 3/4" in order for the distributor cap to clear the rear bulkhead.  After doing that I set forth fabricating the transmission mounts.  They came together rather nicely.  I need to clean up the welds and paint them.  I also spent some time fitting the exhaust head shield.  I made a bracket to hold the height and center the shield around the mufflers.  I'll finish it off by creating a support for the rear of the exhaust.  I need to put the rear clip on and check clearance.   I also fitted up the headers and MSD ignition.  I have some aluminum and stainless tubing bends on the way to create a water neck and complete the cooling system connections.  Hopefully I'll be able to fire the motor in the chassis in a few weeks.

March 21, 2003 - Dyno time....  Look here.

March 16, 2003 - The headers are finally done!   A friend TIG welded all the tubes together and I MIG welded the collectors.  Thanks to Bob at Bob's Homebrew in the University District!  The mock-ups for the exhaust can be found here...  I also fabricated an alternator mount which placed it quite low.   I'm in the process of bending the exhaust shield into shape.  A new belt, oil filter, and it's off to the dyno.

March 2, 2003 - I spent the last few days tacking up the headers.  They turned out reasonably well. Now it's time to weld the tubes together.  I also fitted the rear sway bar.  Time is flying but hopefully I'll have the headers ready in a week and off to the dyno.  Header pictures are here...  I've spec'd a set of Borla XR stainless mufflers. Next week they be installed.

February 24, 2003 - Last weekend I had a few people drop by from the GT40 forum.  I didn't get much done but I did get some guidance on the headers.  This weekend I cut the flanges between each tube so I could work one tube at a time.  Things are coming along.  I have four tubes complete.  Unfortunately my chop saw have a minor problem so I'm waiting for a replacement part before continuing.  Ever try to make straight cuts with a hacksaw!?  Pictures are here...

February 11, 2003 - I spent some time working up an alternator bracket using a March unit.  Unfortunately, the Trickflow head holes are a bit off from those of the bracket.  More to come here as I think I've found a solution.  I started to word on the headers and came to the realization that I need to either learn to weld or get out the check book.  The elusive skill has haunted me for years.  I stick welded and brazed years ago but never stepped up to the real deal.  I decided to purchase a MIG welder and have a go.

February 4, 2003 - The engine is in!  Just a trial fit for all the accessories.  I'll be working on the headers.  They really worked out well as a starting point.  Here are the pics...

February 1-2, 2003 - A week in China and a week to recover results in little progress on the car!   I'm back to it this weekend.  I've finished the installation of the fuel pump and filter system aside from a few fittings. Note the solenoid valve that allows switching between tanks and maintains the return line for the carbs.  The tanks have been mounted and all filler hardware installed.  The last step is to wire the pumps and valve setup.   I also began fitting the motor to the transmission.  Adapter and flywheel are installed.  Mental note:  Always apply thread sealer the the flywheel bolts otherwise you develop a slippery clutch!   Hopefully I can install the engine and transmission in the chassis and begin work on the header later this week.  Then I'll pull it and through it on the dyno.  Photos of the setup are here.

January 3, 2003 - Welcome to the new year.  It's been six months since the car landed and things are coming along.  I spent a few days fitting up the door latch internals, aligning the front end, fabricating and installing the rear window, and insulating the interior.  The dash has been test fitted and the defrost grill installed.  Wiring almost complete.  I'm still waiting for my cam so the motor progress has come to a halt.  Hopefully I'll have some time this month to fabricate the headers and get the motor fired.

December 28, 2002 - I received a beautiful steering wheel hub made by a friend for Christmas.  The center emblem was very sneakily ;-) obtained from a fellow on the GT40s forum.  Check out the pictures.  Note the new reading material!

December 21-23, 2002 - I spent a few days cleaning up and installing the gas fillers Here are a few pictures.  They came together fairly well.  I've been aligning the front end and working on the latches.  I have a few weeks off so progress should be good.  Still waiting for my cam and distributor...  :-(

December 14-15, 2002 - Get out the nutserts and stainless button heads.  I installed the windows and light covers.  #8 stainless button head screws and washers work well.   The covers required minimal trimming.  Somewhat laborious work...  Fit the window, drill 3/8" holes through the lexan and fiberglass, remove the window, drill the glass holes out to 1/4", install the nutsert, install the window and voila!  Time to get the sanding block out and finish blocking the body.  My cam is in transit (so I was told 12-23-02) so the motor should be finished up soon.  The doors still need some tweeking and the latches need to be mounted.

December 7, 2002- I'm still waiting for my cam and ignition so engine progress has been slow.  I spent some time aligning the doors and setting up the latches.  In general, they are in pretty good shape. The hinges offer enough adjustability to get them close.  The gaps need sanding to even them up.  The latches proved to be interesting.  I'm using Bear Claw double locking latches mounted externally on the door.  I mounted the striker pin only to find there is an inch gap between the latch and pin.  I knew this was going to happen but I thought I'd try...  Here are some pictures.  Time do chuck up some aluminum and make some one inch spacers.  I've also fitted up the front clip latches but need to work out the details for the clasps. Once all the hardware is mounted I'll begin blocking the rest of the car.  

November 28, 2002 - I did a dry fit of the engine.  I need the cam before I can do final assembly.  A couple things came up.  The valve covers need the breather bosses clearanced as the roller rockers hit them.  The throttle linkage on the webers will become a side pull as the bell crank conflicts with the rocker covers.  The headers look like they will work well.  The collectors need to be repositioned but the height and chassis clearance on the sides looks OK.  Once the motor is together I'll work on these.  Then its off to the dyno.

I hit the 10 meg space limit of my web.  Fortunately I have some other space that allowed me to move older photos.  

November 26, 2002 - My heads arrived.  Total Engine Airflow did the works on them.  They look outstanding.  Intakes are matched to a FelPro 1250 gasket.  Exhausts are hogged out too.  Combustion chambers are milled to 58cc giving an effective compression ration of 10.4 to 1. Flow reaches 305 cfm intake and 227 cfm exhaust.  This is the real deal.   Once the cam and ignition arrives I can assemble the engine.  Dyno time is nearing...  Can we reach the 450hp mark?  I say "yes!"

November 24, 2002  - Progress is slow as I'm waiting for engine parts.  I've done a bit more work with the wiring and interior.  This weekend I visited GT40 #1033.  Here are some pictures...

November 1, 2002 -  My Weber 48IDAs arrived from Pierce Manifolds.  They are neat!  Check out the pics.

November 8-9, 2002 - Work slowed a bit as I needed to make a cam selection.  I'm working with Levy Racing. (Fair warning, I've waited six weeks for parts and still haven't seen them.  Gordon may know his stuff but speed is not his forte.  12-23-02)   We came up with a custom Isky grind the will fuel the beast.  So the cam and ignition are on the way.  Oil control is installed.   The final induction decision is...  Weber IDAs.  Pierce Manifolds is supply the setup.  It should be here next week.    I've continued to work the wiring and am nearing completion.  The wiper motor auto-part has been a bit of a mystery.  Perhaps I'll post an image with the puzzle.  I also found a Zepher vent for the dash via GT40s.com.  Check our the interior section.

October 26-27, 2002 - I love to come home and see large boxes at the door.  The headers and bends are here.  Check out the pictures.  These look like a good starting point.  I need to get the motor set before I can fit them.  Heads are on the way with a bunch of tidbits to finish the engine.  Injection or Webers... That's the question.  Wiring is looking good.  All lights are functioning.  The mustang turn signal switch is working well.  I have a few details to finish and am awaiting a few toggle switches.  

October 19-21, 2002 - I spent the better portion of the weekend cutting holes in the dash to fit the Autometer gauges.  Check out the interior pictures.  A minor F$%k up as I scored the dash with my hole saw.  It won't be visible when installed unless you are upside-down.  The mechanical water and oil temperature gauges have capillary tubes that may be too short to run them to the engine.  The water temp can tap off the front radiator inlet.  The oil temp is another story.  I may need to send them back to get the senders extended.  I need to get some toggle switches for lights and fan.  I may use a late model mustang stalk for the beams, horn, and wipers.  I have one on the way.

I installed new seals in the Audi gearbox.  It should be together before weeks end.  The short block is assembled too.  Check out the pictures.  I'm undecided on heads.  The pistons are clearanced for Trickflows.  I think I'll get a bare set of TFS heads, clean up the bowls, port match and put stainless valves in them.  I'd like 425-450HP and this should support it.  Cam is undecided as I've yet to choose between Webers or stack injection.  Choices, choices...  Headers are in transit Schoenfeld 180º SBF units along with some extra bends from Speedway Motors.  

October 12-13, 2002 - I installed a Phantom Grip in the differential.  This is a slip-based traction control device. It's basically a billet with four springs.  The face of the billet pushes against the spider gears in the diff causing it to lock.  When cornering the slip will vary left to right so as not to act like a spool.  It's a bit of an experiment but hey, the price is right.  Time will tell. Use their Porsche 924/944 kit.  Look here for pictures  

I also finished installing the front indicators.  These are Lucas 488 turn signal/running lights from Finishline.  Look here for pictures.   The wire routing is nearing completion.  Brake lights work.  The balance of the system will need to wait until the ignition and gauges are in.   I order a set of Autometer Cobra gauges from Tristate Motorsports.  They look like Smiths gauges but have contemporary movements.  I found a screaming deal on the FFCOBRA board.

The block work and balancing is complete.  The short block should be ready this week.  I'll focus on getting heads on the motor and working on the transmission mounts and headers shortly.

October 3-4, 2002 - The block is off to the machine shop for a bore and hone.   The rotating assembly is ready to be balanced.  It should be 2-3 weeks before the short block is back.  The car hit the ground this week.  You really don't realize how low these cars are until you fit up the wheels.  Look here for pictures. The pictures don't do it justice.  I've mounted some fog lights in the lower openings and am awaiting the Lucas indicators.  Wiring is progressing.

September 25-26, 2002 - The tires are mounted.  I'm waiting for some pin lugs from PS as they sent me the wrong thread.  Almost on the ground!  I finished the interior aluminum. It looks good but will be covered up soon enough with carpet.  I started the wiring.  I'm using a Painless 18 circuit model.  The only odd ball setup will be the two fuel pumps and level senders.  There is provision for one level sender and I'll run another wire for the second.  I'm going to use the two power window circuits for the pumps and forego the regular lead.  I need to get some relays for the headlights, fuel pumps and fans.

September 23, 2002 - My BRM wheels and tires arrived today.  They look awesome.  Look here for pictures.  

September 20-22, 2002 - I mocked up the transmission and engine block in order to set the mount positions.  Look here for pictures.  The mounts have been bolted in place.  The engine is set as low as possible.  The limiting factor was the transmission which now sits about 1/2" from the cross member.  I'll need to fabricate a transmission to frame mount but that can wait for now.  The engine block will go out this week for machine work and assembly will begin.  I'm waiting on the fuel system until the engine nears completion as I need to determine clearances for the front drive, alternator and A/C compressor before mounting the pumps.  My tires arrived and wheels should be in on Monday.

September 15-16, 2002 - Stay out of the garage Neal...  One of those weekends.  Tried to bend up some foot boxes.  Look like crap.  Tried to bleed the rear brakes, two bum flares!   Tried to fit up the fuel system.  Is there enough room?  Better wait.  Tried to assemble some push-on hoses.  Push on, more like hydraulic press on.  My hands are shot.  Oh well.  On a better note, my Kennedy Engineering adapter, clutch and starter came.  Nice looking stuff for a reasonable price.  I did redo the flares and the brakes are officially complete!  Maybe this week will hold more promise... 

September 7-8, 2002 - I sanded the rear clip.  Overall it looks great.  There are two seams that will need attention but otherwise it will be fine.  I mocked up the heater and will be mounting it this week. I've also ordered my fuel system components. I've going to us a Grant 14" Corvette wheel.  It's similar to an original in that it has no dish and slotted spokes but is 14" in diameter.  I'll machine a hub cover and mount it to a Grant column adapter. The front brakes have been bled.  I'm waiting for some 45 degree adapters for the rear.

September 1-2, 2002 - Spent a bit of time fastening the brake lines to the frame and routing the clutch line.  I also ordered an Audi 016 to Ford adapter from Kennedy Engineering.  It is 2 weeks out.  I've rethought the fiberglass foot boxes and have decided to bend u[ a set in aluminum.  I'll order up some 6061-T6 sheet stock this week.  I cut out the louver and engine holes in the rear clip.  I also spent some time cleaning the cladding.  It's almost time to fasten it.

August 30, 2002 - I installed the parking brake cables.  I machined some rear caliper attachments.  I used Lokar cables.  

August 25, 2002 - Cleaned up the workspace and detailed the steering column and shifter.  I bent up some templates for the radiator hose connections.  Now I need to source the hoses.

August 24, 2002 - Mounted radiator fans and final routing of brake lines.  I ordered my BRM pin drive wheels from PS Engineering, 7"x15" and 8.5"x15".  Tires are next.  I think 215/60/15 and 265/60/15 or 275/50/15.  I also replaced the metric front studs w/ 1/2"-20 pieces so front and back match.

August 18,2002 - Mounted master cylinders and routed the majority of the brake lines.  I also mounted the radiator.

August 14, 2002 - Received pedals and checked fit.  Too wide for my 10D feet.  Removed 3/4" from pedal assembly.  Looks like this will work well.

August 10/11, 2002 - Fit front brake lines and reviewed routing of rear brake lines.  Fitted radiator and fabricated mounting brackets.  Sourcing fans (10" SPAL x 2) and condenser for A/C.

August 7, 2002 - Fitted the front calipers.  The rotors are DBA aftermarket.  The clearance it tight, but OK.  The rear parking brakes are mounted also.  Next will be the rear calipers.

August 5, 2002 - The calipers arrived from Behrents today.  Great service and a killer price on billet calipers.  Pictures to follow.  Tilton floor mount pedals are on order from Jegs.

August 4, 2002 - Spent a fair amount of time fitting the first headlight.  These are tight. I opened up the rear inner fender to make room to move things around.  After working the cutout to size I fabricated upper and lower mounts from aluminum.  I then epoxied these to the body.  The result is a safe, tight fitting light with full adjustability.  I'll fabricate some inner fender covers from sheet aluminum and screw them into place so that I can access the lights later.

August 3, 2002 - Cleaned up the gearbox and removed the main cluster.  Looks very good.  Ready to install the Phantom Grip into the carrier.  Drew a template for installing the taillights. I also cleaned up the headlights and painted the mounting bezel.

July 30, 2002 - Sportsman block clearanced and short block component pictures posted.

July 26, 2002 - Car arrives and is unloaded from 20' sea container.  Gallery updated