dash replacement

Starting with the old.....the original dash was 1/8 plywood padded with 1/8 foam and covered in vinyl.  It has not aged well. Several of the switches were removed from the front rather that the back as the core wood material had decintegrated.  

Dash Removed - wiring was a mess to start.  

- Several segments were removed. 

-  All Wire taps removed

- Twisted together grounds all removed. 

- all ground connections were replaced. 

- all open hot wires sealed with heat shrink.  Over all the electrical system is now safe and reliable.

Dashed cutout - using the original as a template the new dash was formed in 18 gauge sheet metal.  The depth of dash was reduced to add approx 2cm of additional clearance for my knees.  The straight lower edge was formed to a smooth radius that forms to the lower cross brace.  

Dash covered in vinyl - after several test fit sessions, the dash was covered in marine-grade leather-look vinyl.  The look is very close to the original but should weather much better.  The vinyl was bonded directly to the metal dash.  A much crisper look to the final product.  

Installed and rewire started

underside cover installed.     The switch labels and matching switch bezels are still on backorder.  

Toggle covers added to Wioer, fuel and AFR switches

cool air vent for footwell

In summer driving the footwell gets too hot.  As in 120F hot.   Thermal solutions only go so far as the primary issue is that the air in the footwell is a negative pressure zone and does not move.  It is bearable when moving but at slow speed, the driver's left leg below the knee is scorching.  The solution is to add a vent to each foot well. 

Step 1 was to install a NACA duct under the car below the carbs.  The fresh air will be sucked into the low pressure zone in the foot well via the 76mm high temp hose. (black hose in the pic above)

Step2) 3 inch high temp hose covered with high temp exhaust wrap.  As the vent hose is sitting on the transmission and against the rear of the engine any heat reduction is a positive.  

Step4) install 76mm to 2 port 51mm splitter through firewall.  this was sourced from Demon-Tweeks in the UK. 

Step 5) install vents in footwell.  Each vent can be set open/closed and directed 360deg.  This will allow flow to be adjusted for best results. 

Note: inside ductwork was completed while the dash was out for ease of access. 

Fuel Gauge

Upgrading to Smiths Fuel Gauge and Smiths Ammeter

non matching VDO gauges are out.  

Horn Button

Refreshing the horn button on the Personal steering wheel.   The Personal brand is made by Nardi.

starting point

then added 16 guage base to super 7 emblem

then painted base to a fender matching yellow and installed

final dash look installed

Seat update

Installed Sabelt cushions to back and base.  Completes the look a is comfortable for longer trips.  

smiths speedo cable

Symptom: Smiths speedo was bouncing 40kph.   

Fix #1:  removed the speedo cable and inspected the speedo.  Attached a drill and ran it in reverse with a consistent smooth indicator.   The speedo operates correctly.

Crimped speedo  end of cable was damaged and cable did not sit snuggly.   Installed a diy crimp and soldered the end of the cable.

Results: were much better with 10kmh bounce but the repair did not last.  After a few weeks the bounce started tonincrease again.   After removing cable again the fitting was loose and the soldered end was worn.  

Repair #2:  sent the cable to vintage British bikes in Red Deer Alberta.   The cable was shortend 1/2 inch and a new crimped end was installed.

After reinstall and test drive the cable and speedo are as good as new.  

Floatless Fuel Tank Sending Unit

The seal at the top of the fuel tank for the Sending unit started to leak.  The garage was filling with gas fumes and the float-style sender was bouncing when driving.  The overall accuracy of the old float style was also in question.

I removed the old sender and replaced it with a new Tanks Inc 9" floatless design. The Sender is Smiths Gauges standard 10-180 Ohms.  If I ever decide to replace the Lamco Fuel Guage with a Smiths it will be compatible.    The top and bottom of the tube have a 2mm hole to allow fuel to fill the tube.  The entire tube contains the fuel so that movement when driving is kept to a minimum.

The sender is connected to the LamCo Adjustable fuel gauge. 

On each side of the Light bulb socket is an adjuster for the Ohms for full-tank and empty-tank. Full was adjusted.  After driving I will have to reset the empty level. 

Adjustability was not sufficient.  Purchased smiths 10-90 ohm fuel guage.    With the 1" space to bottom of the tank I should have a 3 to 5 liter reserve.   Currently at 160km and 1/4 tank left.   Will refuel at indicated empty.   The recalibrate reserve capacity.