06/11/04
With all the drilling and grinding done, it was a very quick job to refit the chassis to the front subframe, bolt the wheels on and push it outside. The car in this state is still ridiculously light. It was a very dull day, so the pictures aren't brilliant.
One day, I'll manage to hold the camera level.
It has given me a real boost to see the car outside on its wheels. I'm really pleased with the progress to date. I know it isn't rocket science, but I've found the build to be very rewarding and enjoyable. I've made a couple of daft mistakes, but had no major problems or disasters. So far, so good.
I'm keen to retain the Metro's left column stalk and the top and bottom shrouds. What you can see here will control the side lights, dip/main and flash, direction indicators, hazard warning lights and the horn. I hate dash-mounted toggle switches.
To get the upper column in the right place to allow the switches and shrouds to fit, I've used four penny washers under the top mounting. For the lower mounting, my neighbour Rod used his trusty Myford to make some 30mm long spacers from a piece of steel tubing I had lying around.
The original gear lever gaiter from the Metro is now used as a gaiter for the steering column.
14/11/04
Brake pipes are next on the agenda, starting with the rears. The first pipe goes from the lower outlet on the master cylinder, through a grommet in the hole drilled in the pedal box top plate..
...down to the rear brake limiting valve which I've bolted to the very bottom of the O/S/F bulkhead. This camera angle is rather deceiving, but the valve and pipe are well clear of the clutch pedal throughout its travel.
The next pipe runs from the limiting valve along the O/S lower chassis rail to a T piece screwed on to the O/S rear flexible hose. Usefully, Onyx supply some large-bodied male unions in the kit, which enables the original T pieces from the Metro to be used.
A third pipe runs across the rear bulkheads to the N/S flexible hose connection.
Finally at the rear, I've made some new pipes that go from the bulkhead flexible hoses to the wheel cylinders. The original Metro ones were far too rusty to use again.