www.Zetec-Cat.co.uk

Build Order

The build manual doesn't provide a particularly good idea of the order in which to build the car. To help, I have written this page which is loosely the order in which I built my car.

I have modified it slightly in that originally I fit the Sierra pedal box and, only after installing the Zetec engine did I find that I couldn't use the Sierra pedal box and had to replace it with a Stuart Taylor floor mounted pedal box. Apart from the pedal box problem which I couldn't have anticipated, I had no problems having put something in and then having to remove it to get something else to fit later on.

Starting with the chassis upside down on build stands:

  • Aluminium floor panels (don't drill or rivet outside edges though)

Turn the chassis the correct way up:

  • Aluminium panels:
    • A panels
    • Footwell end panels
  • Pedal box
  • Cut and drilled (but not riveted) aluminium panels:
    • Tunnel sides
    • Seat backs
    • Rear of parcel shelf
    • Battery tray
    • Bottom of parcel shelf (rivnut / self tappers)
    • Tunnel top (rivnut / self tappers)
  • Brake lines, fuel lines and loom cable tie bases
  • Steering rack
  • Steering column
  • Front suspension including hubs
  • Rear subframe, differential, suspension, driveshafts and hubs

The car was then removed from the build stands and onto the donor wheels.

  • Rear of parcel shelf
  • Exterior side panels
  • Petrol tank
  • Rear inner wheel arch panels
  • Scuttle
  • Rear tub
  • Windscreen supports, frame and mirrors
  • Engine and Gearbox
  • Prop shaft
  • Gear remote
  • Riveted on interior aluminium panels
  • Dashboard
  • Nosecone
  • Loom
  • Radiator, coolant hoses and heater
  • Started engine
  • Brake fluid
  • Tunnel top and parcel shelf panels
  • Interior covered plywood panels and 'boot' lid panel
  • Carpet
  • Seats and seatbelts
  • Cycle Wings
  • Windscreen
  • Lights
  • Exhaust
  • SVA trim

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