Build Checklist

This checklist is broadly in the order I built the car, acting as both a checklist and a measure of progress against the overall goal. I didn't follow it religiously, just ticked things off as I got to them, added new ones as required and hi-lighted steps that I needed to go back to.

Having the build sequence roughed out helped me think through any dependencies; its all common sense + reference to existing knowledge from the Factory, other builds & online forums.


During the build I coloured each line  to tick them off but removed the lot as a final check
Green = Complete, Yellow = Work in progress, Red = Flagged)

Laterly used as a general to-do list




Donor Parts
  1. Diff: Clean & paint
  2. Diff: Replace shaft oil seals
  3. Diff: Replace pinion shaft oil seal
  4. Shafts: Clean & paint
  5. Shafts: Replace CV boots
  6. Rear hub carriers: Clean & paint
  7. Rear hub carriers: Replace oil seals
  8. Rear hub carriers: Grease
  9. Front uprights: Clean & paint
  10. Replace wheel studs x16 - needs 47mm studs

Take delivery

  1. Gearbox
  2. Zero Kit

Chassis on high stands (max 450kg)

  1. Panel: Seat back
  2. Under seal exterior rear axle well & floor panels
  3. Fit Differential
  4. Check seat belt attachment points are accessible & clean (photograph mounting points)
  5. Pedal box
  6. Master Cylinder
  7. Brake lines Rear Front
  8. Steering column
  9. Offer up Steering rack
  10. Panel: Drivers side tunnel & bulkhead
  11. Panel: Drivers side crescent
  12. Panel: Passenger side bulkhead
  13. Panel: Drill & prep all passenger tunnel panels
  14. Panel: Drill & prep passenger side crescent
  15. Rear suspension
  16. Rear shafts
  17. Rear discs, calipers & hand brake lines (hub nuts torque later)
  18. Front suspension - remember IVA boots
  19. Steering rack - leave ball joints loose!
  20. Front discs
  21. Hand brake - Check I'm using the top hole on the lever
  22. Swirl pot & bracket
  23. High pressure fuel pump
  24. Low pressure fuel pump/filter
  25. Prop shaft
  26. Carpet - O/S, Floors & footwells

Rolling chassis

  1. Lower onto wheels so the chassis is mobile
  2. Low pressure fuel circuit Front Back
  3. Clean & mount fuel tank
  4. Rear Panel - don't forget holes for spare wheel carrier 
  5. Speed sensor bracket
  6. Fix gearbox mounting rubber
  7. Chassis loom
  8. Battery loom

Engine Prep and install

  1. Replace sump
  2. Thrust bearing/spigot
  3. Remove inlet manifold
  4. Remove exhaust manifold
  5. Remove thermostat housing
  6. Offer & check fit of new inlet/fuel rail/plennum
  7. Bell housing starter bulge adjustment
  8. Mount gearbox to engine
  9. Mount starter motor to engine/gearbox
  10. Oil pressure sensor
  11. Offer Engine/Gearbox to chassis 
  12. Engine mountings
  13. Install Engine/Gearbox combination 

Engine Services

  1. Plenum/Injectors and Air intake - clean & fit 
  2. Idle Air Control Valve - My Direct mount
  3. High pressure fuel circuit
  4. Alternator
  5. Engine Loom
  6. Engine earth strap
  7. Horn 
  8. Radiator
  9. Fan
  10. Cooling circuit
  11. Exhaust manifold - offer
  12. Oil breather pipes/filter

  13. Differential oil
  14. Gearbox oil
  15. Engine oil

Finishing

  1. Panel: N/S side tunnel
  2. Panel: tunnel top
  3. Adjust speed sensor

  4. Carpets - Seat back panel, N/S footwell, Boot
  5. Vinyl - Tunnel top & aux panel 

  6. Front suspension off & onto axle stands N/S O/S
  7. Panel: nearside side panels
  8. Panel: offside side panels 
  9. Front suspension final fit & torque N/S O/S - remember IVA boots & copper slip bolt shafts

  10. Fit Scuttle
  11. ECU, Fuse Box & Heater 
  12. Fit Battery tray & pedal box cover
  13. Fit Nosecone 
  14. Fit Bonnet

  15. Headlamps
  16. Front Indicators

  17. Rear suspension final torque
  18. Rear hub nuts torque
  19. Steering rack torque
  20. Lower steering column
  21. Front brakes & lines N/S O/S
  22. Tyres, valves & balance wheels
  23. Front Wheels
  24. Rear Wheels
  25. Torque suspension nuts
  26. Fill and bleed brakes (re fit/measure 43mm rear bolts & lock washers)

  27. Rear wheel arches 
  28. Rear lights

  29. Boot cover

  30. Dashboard loom
  31. Dashboard  

  32. Check loom - functionality - dash/lights/stalks
  33. Boot floor

  34. Manifold - final fit
  35. Bonnet Manifold opening
  36. CAT & Silencer

  37. Find the front nearside brake caliper spring & fit

  38. Nosecone grill
  39. Wing mirrors - cover the nuts, shrink wrap
  40. Rearview mirror

  41. Front wheel arches
  42. Seats, Seat belts

Engine first start checklist

  1. Check Diff has oil
  2. Check Gearbox has oil
  3. Check Engine has oil
  4. Check Cooling system has coolant de-ionised water + approx 30-50% antifreeze
  5. Check oil pressure
  6. Check fuel system - no leaks in LP or HP side
  7. Start

IVA

  1. IVA Prep - VIN x2
  2. Check torque page is complete

  3. Calibrate Speedo
  4. Configure ECU
  5. Align headlamps - roughly, hoping I can adjust during the test
  6. Align wheels

  7. HP Fuel pump - attach with metal/rubber not cable ties

  8. Gear knob
  9. Heater knob - remove Wiper motor & washer reservoir
  10. Brakes - check pads seated correctly & bed in/degrease disks
  11. Check all trims in place - no edges

  12. Insurance

  13. IVA Test - 30/5/2013 - Passed !

DVLA

  1. DVLA Registration & Tax
  2. Number plates

Post IVA & DVLA

  1. Steering wheel
  2. Windscreen
  3. Spare wheel carrier
  4. Weather gear; doors, half roof
  5. High level brake light
  6. Front mud guards
  7. Bonnet vents
  8. Badges - union jacks, GBS & Zero

General To-do list/notes - Feb 2014

  1. Half roof - done
  2. Rear wheel arch guards - done
  3. Bonnet locating pins - done
  4. Speaker high pass filter - done

General To-do list/notes - October 2014

  1. Re-paint wing mirror backs - done
  2. Check cooling system, thermostat, flush and refill anti-freeze - done
  3. Swap out radiator fan for large pusher - done
  4. Secondary ground line to block & chassis for the alternator - done
  5. Paint spare wheel retaining threaded rod - done
  6. Washers/waterproof windscreen to scuttle mount to avoid wet feet - done
  7. Grease propshaft UJs - done

General To-do list/notes - January 2015

  1. Replace timing belt - done
  2. Pedal box cover edge around brake fluid reservoir/scuttle runoff - done

General To-do list/notes - April 2015

  1. Radio headphone circuit - done

Post Scotland 2015 - Things to check/amend

  1. Rears rubbing the arches sometimes - done
  2. Windscreen chip - ignore - done
  3. Front number plate bracket - done
  4. Quick Rack - done
  5. Headphone circuit adjust - done
  6. Radio aerial double check - done
  7. Passenger foot rest - done

Post Barcelona 2015 - Things to fix

  1. Boot edge trim - done
  2. Silencer rattle - done
  3. Change headlamps - done

No comments :

Post a Comment