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 build 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