Westfield Kit Car Build Diary

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The Build Diary - Module 5

Scuttle -	Fit the Body -	Rear Arches -	Rear lights -	Roll Bar -	Bootbox
Windscreen -	Transmission Panels -	Filler Cap -	Exhaust -	Coolant -	Inner Panels
Heater -	Lights/Indicators -	Bonnet -	Nose Cone -	Catch Tank -	Spare Wheel

Module 5 Build:
<8th November 2005>

Scuttle:
Whilst waiting for the engine to be sorted I decided to see what work needed to be done to the scuttle, as this needs quite a few additions I figured i could get a headstart.
First thing i noticed was it needed a small arch cut out the bottom to clear the steering column. I figured the best way to cut this was with a drill type saw, so i bought an Omnisaw from Screwfix and it seems to work perfectly. Using this and a smallish cutter i was able to cut the hole pretty much to fit and then filed down the edges.
Once this was nice and neat I ran a small piece of rubber edging round the cut edge to finish it off. As you can from the pics below it seems to fit pretty nicely.

<15th November 2005>
The next modification to the scuttle is to cut out the vents for the demisting vents. There are three vents preformed but uncut on the scuttle. To cut these neatly i measured from the edge of the omnisaw guard to the cutting edge of the cutter, then i placed blocks of wood on tissue to protect the surface and clamped them at the right distance to run the cutted guard along.

This produced relatively straight grooves for the vents that i then simply filed down with very fine neddle files. The result is pretty neat and tidy.

<24th November 2005>
Todays job is to fit the demist ducting to the underside of the scuttle. This is some fibreglass that cups around the demist vents and has 2 inlets for the heater unit to connect to. The first thing to do with this panel is open up the ends of the heater inlets, so i drilled one hole through these and then used the omnisaw to open these up to the full openings you can see below.

Then i trial fitted the ducting in place so once i had the adhesive on i could quickly get it stuck on.

The adhesive i used was Beta Steel as this is what my local auto shop stocked, this is the same as the one Westfield recommend just a different brand. A word of warning though this stuff is really hard to get off your skin so if you have some rubber gloves it's best to use them. I didn't and so i have been trying to scratch it off for days! This goes on like silcon sealent and so i put a line around the border of the panel as you can see below

Then it's just a case of fitting it in place and pressing down aling the edges. It sets to a plastic in a couple of hours so i left it a few hours and then placed it on the chassis to fully set.

<29th March 2006>
ECU Cable