Parts & Tools

This is a log of components which ended up on/in the car or tools bought to complete the car during the build.

More pages

• Follow this link for a page on Tools used in the initial build
• Follow this link for a page on the Clocks
• Follow this link for a page on ECU Configuration
• Follow this link for a page of parts used in Maintenance 

GBS Zero Kit

• Order #1: Zero GT 'Full Kit' except: Seats, Windscreen, Wipers, Silencer & Mirrors
• Order #2: Seats, Seatbelts, Wipers, Instrument surround, Badges, Mirrors, Boot cover, Brake & Gear gaiter, Silencer & CAT, Windscreen kit
• Order #3: Extra trim, extra silicone hose for overflow, fog & reversing lamp bulbs, new style VIN plate

Donor Parts

Parts which GBS can supply reconditioned but can be obtained from a donor vehicle - in my case I sourced these separately in reconditioned/as new state or reconditioned myself.

• Ford Type 9: 5 speed gearbox, bell housing, clutch release arm & gear lever
• Sierra steering column, cowls & switches
• Sierra front uprights & hub assemblies
• Sierra open differential 3.62 ratio
• Sierra push in drive shafts, hubs & hub carrier assemblies

Other parts

Either because they were not in the GBS kit, I changed my mind during the build or I preferred to source elsewhere:

Weather protection - soft

• 7.9mm fibreglass tent poles
• M75 Red thread
• 1000 D PU Waterproof Cordura fabric
• 1" Bias binding
• Lift the dot fixings
• Black open ended no.10 zips
• 25mm webbing & fittings
• 50mm webbing & fittings
• 1" flat elastic

Weather protection - hard

• 4mm thick PETg - wind deflectors
• Lift of hinges

Lambda

• Lambda plug for GBS loom - Deutsch DTM 4 pin
• Narrow band lambda sensor - universal 4 wire

Heater assembly

• Push Pull knob & cable - heater water control
• Savage latching switch - 'fan'
• 5/8" bolt on take offs - heater feed from main cooling pipes
• T7 Design 3.5kw heater unit
• 2" Heater duct
• 16mm & 13mm heater hose
• 2x 16mm to 13mm host adaptors
• 16mm taxi heater valve
• 4x Heater outlets
• 12v 10a PWM controller - for the heater fan
• 1/4" BSP to 5/8" BSP adaptor

General parts

• Universal mud flaps - modified for the front
• Molybdenum grease
• High level LED brake light
• Locking wheel nuts
• Wire wool - to quieten silencer
• Wire mesh - to hold in silencer wire wool
• Plasterers bead corner - to make brackets for cycle wings
• Car Interior mounting clips
• Inside doormat for under dash covering
• Exhaust Gasket
• Foam draft strip - to seal scuttle/firewall
• Extra brake line - to replace damaged offside line
• Spare ECU connector pins
• Seat runners x2 dual locking
• Stainless 0.9mm thick & Aluminium 1.2mm thick sheets for various fabrication
• 1kg Fire Extinguisher
• 2 way waterproof connector - for extra number plate lamp on removable spare wheel bracket
• Savage latching switch - 'boost' ECU map selector 
• 2x M10x35mm Lamp nipple tubes & nuts - front indicator extension mounting
• Tarpaulin 20mm eyelets - boot cover around seatbelt mounts
• Battery terminal covers - starter motor terminals
• Cable clamp - backup clamp for the accelerator cable
• Exhaust heat wrap & jubilee clips - manifold perm & IVA temp to cover exhaust 'edges'
• Steering rack gaiters (Peugeot 205)  (40mm diameter) - IVA indicator extensions
• Short Battery lead +ve - to fit FIA switch between battery & fuse box
• Spare wheel mounting - M12 x 1.25 threaded rod, wheel nuts & stainless plate
• Nylon pipe 5mm x 1m - to allow vacuum feed to the fuel regulator
• Carpet underlay 10mm & Kitchen cloths - boot floor & lining
• Richbrook Touring silver gear knob
• Heat shrink tubing 5x 1m various sizes - to tidy up various loom to plug ends
• Aluminium flat bar 50mm x 10mm - to fabricate the IACV mount
• Gasket paper 2x 0.5mm A4 sheets - plenum mount & IACV mount
• Wheel studs 16x 47mm high tensile studs
• Black mesh grille - nose cone grille
• Fuel pump inertia switch - not yet mounted
• Various Washers, Nuts & Bolts as required
• Various grommets
• Slide-a-boot x4 Medium - to replace drive shaft boots
• Rear hub oil seal & bearing set (only oil seals replaced)
• Differential oil seal set

Consumables 

That end up on the car:

• Silver Hammerite
• Black Hammerite
• Copper slip
• Loctite 243 threadlock (removable)
• Loctite 5922 gasket paste - to seal the fuel sender & sump
• Sikaflex 291 x2 (I managed to also order the bond from GBS!)
• Underbody Seal
• Multi Purpose Grease
• 5 litre can of petrol - to clean fuel system & tanks 
• Amalgamating loom tape - to tidy up exposed wires
• Fabric loom tape
• 20mm x 3mm neoprene adhesive strip - bonnet fitting

Used during the build:

• White Paint Pen
• Black permanent marker
• Gunk degreaser
• White spirit
• Large Bubble Wrap 750mm x 50m
• Sash cord - general purpose soft rope for holding things temporarily
• Van hire: Extra Long Wheelbase Iveco
• £90 worth of diesel for the van
• Brake and Clutch cleaner

Parts over

Components bought but did not/will not use
(by all means get in touch and make me an offer if you can use any of these)

• Water Temperature sender (spare bought new)
• Front indicator extensions with boots & fixings (sold on)
• Font indicator stalk indicators with lamps (sold on)
• 2x Number plate brackets
• GBS Zetec crank case breather blanking plate
• 2x de-mister vents to 2" pipe adaptors
• Chrome effect rear number plate lamp
• GBS Prototype IACV mounting kit (sold on)
• Wheel studs 16x 63mm (sold on)
• 4x Latching, 1x Momentary Savage Switches