Bristol Kit Car Club and Forum - BKCC

Kit Car Tech Talk And Build Stories => Kit Car Builds - Click Here => Topic started by: Richard on 17, May, 2009, 09:37:15 AM

Title: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 17, May, 2009, 09:37:15 AM
Going to try and post a not quite blow by blow account but at least a few of the stages along the way.

So far I have;
Several Magazines
Several Catalogues
A few spreadsheets
A couple of word documents
Very many bookmarks in Firefox
Tidied the garage a bit even painted the floor.
Ordered a few items.

As you can tell I am truly just beginning.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: chanz on 17, May, 2009, 10:48:32 AM
i envy you lol


good luck tho!
Title: Re: My Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 17, May, 2009, 12:23:37 PM
Hey Richard,

I'm sure you will get some encouragement here. I'm no build expert, but I would love to have a go.

At least your prep is in place, so go for it mate!!!

PS. Sorry I had to edit your gallery so that all your pics are within the gallery folder. In Gallery you have to ignore 'add image to post' its a coding problem I cant sort - instead find use picture as thumbnail tickbox if you want to use an icon. I have added one for you. You can change your icon whenever you like, but clear your internet history and possibly delete all temp files in from your browser to see the change. To upload more pictures just click add picture and then browse your PC and upload (submit) the picture file direct to my server. Any gallery probs just drop me a message.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 21, May, 2009, 07:44:54 AM
More bits on order, all money going out and nothing back yet.

Plan is mid - end of June start build.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: vinny1275 on 21, May, 2009, 08:26:44 AM
Are you doing a scratch build, or getting a kit?
Title: Re: My Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 21, May, 2009, 07:32:45 PM
Quote from: Richard on 21, May, 2009, 07:44:54 AM
More bits on order, all money going out and nothing back yet.

Plan is mid - end of June start build.

It will be worth all the money in the end  ;D
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 21, May, 2009, 08:30:19 PM
Quote from: vinny1275 on 21, May, 2009, 08:26:44 AM
Are you doing a scratch build, or getting a kit?

Went the kit route for first build having no skills in this area or many other really.
Thinking was go for kit, get it done, then play tune for a bit, then if still loving it go for a more ambitious project.
Perhaps a bit lazy and a short cut but for me I think it is the right decision, I have a target of being running on road by Exeter show, which may turn out to be a bit ambitious.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 21, May, 2009, 08:33:41 PM
Hot news:  Decided on paint scheme and colours !


I know, getting ahead of myself  ;D

Title: Re: My Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 21, May, 2009, 08:36:28 PM
Well??

Spill the beans then ;)
Title: Re: My Kit Car Build - May 2009 until ...
Post by: vinny1275 on 22, May, 2009, 08:37:53 AM
Have you decided on a kit though?

G - if you want a hand coding / help with the site I'm a network admin for a ftse100 software company (ooooohhhhhhhh), one of the things I look after are sites / databases we host for clients - I started as a developer so I can do code too - I'm sure I have a PHP book still knocking about somewhere..... :D
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 22, May, 2009, 09:56:27 AM
Kit is decided.

A certain magazine coming out in a few weeks time will have it, was trying to hold off just a little while longer  ;)

Chasing donors at the moment, just soo many options I need a bit of discipline to narrow choice and get stripping.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: YellaBelly on 22, May, 2009, 08:28:21 PM
And so, the choice is?.......
Title: Re: My Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 22, May, 2009, 08:57:02 PM
Quote from: YellaBelly on 22, May, 2009, 08:28:21 PM
And so, the choice is?.......

Second that  ;)
Title: Re: My Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 22, May, 2009, 09:10:50 PM
Quote from: vinny1275 on 22, May, 2009, 08:37:53 AM
G - if you want a hand coding / help with the site I'm a network admin for a ftse100 software company (ooooohhhhhhhh), one of the things I look after are sites / databases we host for clients - I started as a developer so I can do code too - I'm sure I have a PHP book still knocking about somewhere..... :D

Hey thanks Vinny. I'm certainly no expert and in no way a coder. As you can see this site is built on a SMF platform. Most of the mods have been played around with a bit to get them to work on this custom theme, but thats the limit of my PHP with help.

What I am trying to do is get my head round SEO, in particular Google indexing topics. As Google is so slow at registering changes, its diffucult to know if subtle changes I make are making any difference. I have recently applied a mod that automatically creates meta name="description" content and meta name="keywords" so waiting to see the results of that. You can see it at work in view source.

Any ideas on SEO or geneal advice on the site, please let me know. Cheers mate.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 29, May, 2009, 09:43:39 PM
In the end I went for a pretty new car to Kit market from GKD, the GKD Legend.

Quite a hard decision as not many out there to get support or ideas from yet just an incredible amount of BMW knowledge.

Won the donor car now but not picked it up yet, so things nearly ready for construction time, getting quite exciting !! ;D
Title: Re: My Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 29, May, 2009, 10:21:37 PM
Quote from: Richard on 29, May, 2009, 09:43:39 PM
In the end I went for a pretty new car to Kit market from GKD, the GKD Legend.

Quite a hard decision as not many out there to get support or ideas from yet just an incredible amount of BMW knowledge.

Won the donor car now but not picked it up yet, so things nearly ready for construction time, getting quite exciting !! ;D

Great choice I'd say.

The GKD Legend looks very cool, great BMW engine and chassis too. Loads of spare parts as well.

Go for it.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 30, May, 2009, 08:27:46 PM
The BMW engine and running gear do mean a lot of spares / tuning and knowledge around, quite influential.

Went for the donor that had the M42 4 cyl engine, it was the basis of the S42 that BMW used in the Touring car series so in extreme build ended up at 315 in NA form, of course lots of money to get above 250, stock is ~140 but relatively simple to take to 170.

The massive range of parts is really making the mixture of options very extensive.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: David H on 30, May, 2009, 08:35:50 PM
http://www.gkdsportscars.com/pictures-1.html

Nice. BMW running gear is ace. I've had one. Very interesting project. Looking forward to seeing it and belting it down to the Exeter show!
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 04, June, 2009, 10:33:58 AM
A little update.

The prototype gets IVA'd next week, so in theory chassis fine so will be on way to me (via me)  in near future.

Weight distribution looks to be about 51% rear and 49% front, not knowing other kit car distribution of weight I'd imagine they are mostly there or thereabouts.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Bulldog Bri on 04, June, 2009, 10:48:50 AM
need to chat with you at the club re registering and IVAing as thats what I'm about to start and ain't got a clue about it  :-\

8)
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 04, June, 2009, 12:03:34 PM
Quote from: bulldog bri on 04, June, 2009, 10:48:50 AM
need to chat with you at the club re registering and IVAing as thats what I'm about to start and ain't got a clue about it  :-\

8)

Not sure I know enough about it but I have found the various revisions to the original IVA create a couple of items to watch e.g. head rest/restraint padding in original but not in a later revision. May be a case of several heads make light work on this new test.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 05, June, 2009, 10:56:33 PM
donor car now at home - the strip follows with the odd pic
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Bulldog Bri on 05, June, 2009, 11:01:18 PM
Thats the fun bit, Pulling the old car apart. Take it slowly and label as much as you can.

8)
Title: Re: My Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 05, June, 2009, 11:10:59 PM
Quote from: Richard on 05, June, 2009, 10:56:33 PM
donor car now at home - the strip follows with the odd pic

Great news, dont forget the pics  :)
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 17, June, 2009, 09:28:14 AM
Progress being made on donor stripping.
Will post a "strip" in the gallery this coming weekend.

In pulling apart we've been very careful in the labelling, so it adds a little time.

In researching parts I'm finding a few qwirks in these BMW M42 engines, if you have one or are doing this drop me a line if you've not already found them. Quick example the front bolts can come lose inside the bottom oil pan from vibration or impact underneath, this seems more common on the earlier models which may be aligned with a known gasket replacement work at the time.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 17, June, 2009, 03:50:56 PM
Look forward to the pics Richard  :)

I guess every engine has its own quirk, but if it were that serious, you would never see any M42 engines on the road.

Research anything enough and you will always find somthing to make you doubt your decision, I know because I do it myself.  ;)

Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 20, June, 2009, 10:44:26 PM
A short update.

So far this donor car has caused amusement, annoyance and angry abuse.

The full strip is going on, not just a pinch the bits and run.

So mostly for fun the interior is really only left with steering column hot air tunnel and wiring and a lot of wiring it is !!!!

Engine bay is missing a few more parts and access is much improved without the bumper / grill or front strut, i.e. you can walk up to the engine pulleys.

Underneath is now without exhaust and heat shields.

Front uprights are missing 2 of the three bolts on one side.

Violence has been used !   The classic old rusty bolt techniques employed to the full except the trusted swearing (not when finger got in the way of a lump hammer though).

Bolts have had the penetrating spray, the tap with hammer, the tighten then losen, the heating with blow torch (they get very hot), the praying to the god of torque, and the mighty angle grinder.

Tomorrow will undoubtedly see a bit more mess and aggression being used.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 20, June, 2009, 10:55:16 PM
No blood in your build pics Richard, it might scare the kids  ;D  ;D
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Bulldog Bri on 21, June, 2009, 09:56:03 AM
Never bothered my kids when I came in leaking vital fluids, lol.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 23, June, 2009, 03:48:21 PM
A little progress with the "strip" pics going up in next day or so.

Some bolts are truly part of the resistance !

Huge amount of wiring and a little surprise bit of coolant in the dip behind heater in dash.



On new car front a short delay in the chassis being ready as a few minor alterations going on for the first production item.
No changes needed for IVA but a little alteration in case they toughen up and some more beautiful round tubing for nose and to accommodate a slightly bigger radiator.


So angle grinder to the ready for this evenings spark show !
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 15, July, 2009, 09:10:39 PM
Been a bit more progress.

Donor car is now ready for last little operation tomorrow and then it will be dragged away, a couple of its last pics to be posted at weekend coming.

Didn't really need to but the car has been just about totally stripped, no doors, nothing inside except the roof lining and a lot of air.

New chassis is whole and powder coated, a few holes with clips for fuel and brake lines in place. Building some 3D autocad models as we go. At some point we could probably show a layered 3D model so you can strip through the built car in layers, lets see how we get along.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 15, July, 2009, 11:47:38 PM
Keep up the good work Richard.

How about a time lapse video of the build? That would be a first maybe?
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 16, July, 2009, 04:24:05 PM
Good idea !

Working out angles and fixings for a camera over a cuppa and the August Complete Kit Car Magazine.

Had a little quiet smile as it seems the "hole" in the bonnet made it into one of the pictures in the magazine but not one of our pics.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 16, July, 2009, 06:56:24 PM
Quote from: Richard on 16, July, 2009, 04:24:05 PM
Good idea !

Working out angles and fixings for a camera over a cuppa and the August Complete Kit Car Magazine.

Had a little quiet smile as it seems the "hole" in the bonnet made it into one of the pictures in the magazine but not one of our pics.

Good news on both counts.

Maybe theres a 'David Bailey' in our club  :)
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 20, July, 2009, 01:10:45 PM
Solution to pictures found, construction in next couple of days.  A garage reorganisation needed to set it up as best as possible then we'll be underway.

Donor car stripping pretty much complete, just got to arrange its collection and take last bits off that we've left to facilitate that departure process.

Always learning so think a BMW strip post is due separate from this post. For example I didn't de-pressurise the fuel before getting started on strip, so when it came to removing fuel it became a little more exciting than planned  ;D  hey - it worked anyway  ;)
Title: Re: My Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 20, July, 2009, 04:55:58 PM
Look forward to the strip post  ;)

What pic plans do you have then Richard? Make sure you dont blow yourself up first though mate ;D
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 23, July, 2009, 09:01:14 AM
As you may have seen "strip" post underway, some catching up to do on the typing front.

Camera installation in place. Think we are home to Mr Heath and Mr Robinson by the way that got put together, those camera mount screw threads are to a specific ISO standard that is different to other bolts. Found you can buy specific bolt mounts etc. but all are £14+ so given what this is for use of a slightly broken Gorilla Pod, wooden frame, trusty old iron coat hanger and voila one secure upside down fixed camera point that picks up most of the garage and specifically where the action will hopefully get going to completion. Battery charging is a challenge so marked guidelines in place in case we need a recharge or two. Could have used a webcam and sensor but wanted a decent resolution on the pictures.

More items should be arriving the end of this week then earnest building can start, must remember to send the prop off as it is a bit long at the moment  ;), GKD would do it for me but seemed more sensible to send it from here all round.

Still not finalised some of the detail so that will probably be made up as and when we get to it.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 23, July, 2009, 11:25:27 AM
Actually a live web cam could be fun, we could all watch you smashing your thumbs with a hammer  ;D
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 24, July, 2009, 10:27:56 PM
Head needs to be added to thumb list, coming in donor post soon.

A few pics in now, but not yet released. Chassis has moved around a bit a few things marked out and more items have arrived.

We've all been practicing riveting, I suspect I'm not the only one who has done this. Donor car door now being drilled and riveted in curious ethnic patterns.

Title: Re: My Kit Car Build - May 2009 until ...
Post by: Bulldog Bri on 24, July, 2009, 11:06:51 PM
Stop motion pro is a good program to work with your webcam.. You can set regular time intervals for the pic's to be taken then will stitch then together for you...

8)

Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 25, July, 2009, 06:31:47 PM
Quote from: bulldog bri on 24, July, 2009, 11:06:51 PM
Stop motion pro is a good program to work with your webcam.. You can set regular time intervals for the pic's to be taken then will stitch then together for you...

8)

Thanks for that Bri, will check it out when I get a moment.



On car front, been lining up aluminium panels and checking fit. A few small deviations spotted and edges are a bit too rough for my liking so not laser cut. Various sanders and grades of paper out and a little tidying up going on. Some of the welds are a little lumpy (I suspect I am being fussy) so just sanding them back a little to get a better alignment, what is a bit anal is that this is on the bottom of the car !   ;D

Sanding the edges is going from 180 grade to 400 and then 600, not sure if that is best thing to do but it seems to be effective if then buffed afterwards. happy to take any advice or opinion.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 31, July, 2009, 11:24:27 AM
Short update.

Panels all seem a good fit, been aligning them for hole marking and drilling underneath while things upside down, a little bit of tinkering needed on drivers floor pan where it was a little to big.

Started the great bushing squeeze, the old plumbers washing up liquid tip to the rescue. did have the entertainment of watching the odd pushed in bush squeeze itself back out again, this seems to happen when you've not got them equally spaced in their housing.

So slow steady progress, should flip the chassis the right way up again in next day or so.

Title: Re: My Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 31, July, 2009, 08:40:36 PM
Keep up the good work Richard.

I know you have help but dont forget if you need a extra pair of hands just give me a shout.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 31, July, 2009, 10:02:03 PM
Sure, not really getting a lot of time to progress so its being done in little bits, hence the slow progress.

Got the templates made up for the rivet spacing for IVA, one lot at 50mm and other at 25mm, makes it easier to line up, just clamp them in place and drill in holes, well that's the theory ;D

Title: Re: My Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 31, July, 2009, 10:36:08 PM
I know where theres a nice Cobra for sale to tide you over, only joking ;)
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 01, August, 2009, 09:27:42 PM
Really ?  Where is it then ?   ;)


Having a fight with those rear bushes !!!

My vice isn't up to it so I think it is a short trip to the forge for a favour, well a few pounds anyway, anyone got a bench press handy ?
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 02, August, 2009, 09:05:45 PM
A bit more progress today, not spent long and got a few bearings in place.

Seems a few rules and principles involved here that novices like me don't know but you pros do.

Got a good little tip from Pete in between breakfasts this morning, thanks for that it helped along with the other principles !!  ;D

Chassis goes right way up later in the week, and then will be rolling.

Having a few extra paint design thoughts, note to self, must learn to air brush paint.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 02, August, 2009, 09:48:42 PM
Keep those updates coming Richard.
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Bulldog Bri on 02, August, 2009, 09:54:25 PM
Sounds like it's coming along nicely Rich... Post a pic or 2 of the rolling chassis when it done...

8)
Title: Re: My Kit Car Build - May 2009 until ...
Post by: Richard on 03, August, 2009, 12:32:05 PM
Will do a mini pic post update and refresh in the gallery in next week or so, it is more than overdue.

One thing that I'm finding is that building appears to be a more easily done task than pulling apart donor car. This may of course be because I've yet to get to the tricky bits  ;).

All wheel bearings now done, back to those rear bushes next. I would recommend that if anyone else is contemplating building and there is an option to have the bushes pre-installed it is something worth having done if you don't have a well equipped garage ! Still going to get it done now I've started, I want that lining up to be as good as possible.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 04, August, 2009, 05:50:44 PM
Plugging away.

Bushes all in now  ;D

Design of wishbones makes this tougher than it initially appeared even with a bench press.

Had springs arrive yesterday, front ones were not a pair, seems a "special order one" got included by mistake, will now have to wait for postal exchange before progressing there.

I really must hurry up or I'll miss this lovely hot sunny BBQ summer !!  ;)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 10, August, 2009, 10:39:09 PM
Only a little progress last few days, been catching up on chores.

Clamped side panels in place, a little tinkering but not much, appreciate the simple build here, so far a lot easier putting together than taking the donor car apart, however a long way to go yet.

With the 6 cyl Legend now being offered it will be interesting to see who picks which one. We're obviously on the 4 cyl model and as a first build it is going alright, I think having the encouragement of the club helps and well recommended.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 10, August, 2009, 11:40:28 PM
It will be great to see you on the road Rich. Keep up the great work!!

I was only thinking at the meet, it would be nice if a few of us gave you a quick spin in our cars to keep the 'this is what its all about feel'.  Got a bit dark for me at the last meet though ;).
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 11, August, 2009, 02:18:35 PM
Quote from: Richard on 04, August, 2009, 05:50:44 PM


Had springs arrive yesterday, front ones were not a pair, seems a "special order one" got included by mistake, will now have to wait for postal exchange before progressing there.

I really must hurry up or I'll miss this lovely hot sunny BBQ summer !!  ;)

Seems I was showing my beginner status !!    Rear springs same length / size and same writing on them, front ones not same size one one 1cm longer than other and numbering looked different, however, they are the same apparently  :-[   so there you are an embarrassing mistake on my part. Still I'm expecting a few of these types of error on my behalf.

Always learning.

Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 11, August, 2009, 11:09:10 PM
That does sound a bit odd.

How can they be the same if they are different lengths and have different numbers, can you double check?

Just dosent ring true with me sorry.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Bulldog Bri on 11, August, 2009, 11:31:54 PM
Not completly sure, but as the rear of the car doesn't carry quite so much weight, they are a softer rating damper but longer travel alowed in the shock. The set I have on my 7 are shorter for the front

just a thought.

8)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 11, August, 2009, 11:49:51 PM
rear pair were identical front different pair but not a pair or so I thought, will post pics when I get on a device with the photos on.


(http://img199.imageshack.us/img199/660/35734716.jpg) (http://www.postimage.org/)


(http://img21.imageshack.us/img21/359/61971637.jpg) (http://www.postimage.org/)


(http://img198.imageshack.us/img198/691/26596468.jpg) (http://www.postimage.org/)

Now this is where I was a bit naive, as the springs were clearly a different length no just by a couple of mm either and the writing on the one on the left could be read as 360 or a wonky 350 I thought them not a pair.

As said above I am wrong, I did end up wrapping up carefully in a shoe box and posting off.

Obviously once compressed it is the physics forces that count but just didn't expect the difference in the physically to be noticeable to that extent. live and learn - I can hear the more experienced perhaps smiling at this novice mistake.

On the dampers I have reviewed the graphs and they are fine. I have the basic starting set up to file for much later.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 12, August, 2009, 11:22:09 AM
Aha - Appears I am more sane than I've been thinking !

Pair of springs on their way to me and I'll need to find another shoe box or something to post the other one back.

This should not be an excuse for anyone in my household to rush out and buy more shoes !!!  ;D
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 12, August, 2009, 12:02:41 PM
Glad you got it sorted, appears you were given duff info. :o

Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 12, August, 2009, 12:39:02 PM
I think this is a lesson in communication and perhaps a defensive nature of someone who thinks they are being criticised.

I should have paid more attention to detail and so should Damper specialist and GKD, never mind all sorted now in theory, I await package. Teething troubles this one.

What is better is that perhaps I am not insane after all and all those comments by people down the years are wrong  ;)


Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 13, August, 2009, 01:30:41 PM
Early pic of chassis lying on floor.


(http://img15.imageshack.us/img15/4207/65557584.jpg) (http://www.postimage.org/)


Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 13, August, 2009, 11:51:57 PM
Let me guess, you've sat in it right? :D
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 14, August, 2009, 08:04:50 AM
Quote from: G & Toniq on 13, August, 2009, 11:51:57 PM
Let me guess, you've sat in it right? :D
No I haven't, in fact I don't think anyone has. Seats are inside the house in a box and a very brief sit in one of them has happened.


Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 14, August, 2009, 04:50:37 PM
Replacement proper PAIR of springs arrived, yippeee.

The boys in this household are getting weak they can't compress 350lb springs between their hands !

Hopefully a bit of time this evening for another tinker.


Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 14, August, 2009, 04:58:20 PM
Quote from: Richard on 14, August, 2009, 04:50:37 PM
The boys in this household are getting weak they can't compress 350lb springs between their hands !

Ha, lightweights ;D

Good you got the right parts now :)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 06, October, 2009, 07:40:37 AM
Been a long time for an update, not sure if anyone really noticed  ;)

Lots more traveling been done so not as far as I wanted to be so I guess those late night are coming up in the garage.

Suspension is all put together and went in quite easily, the front springs are right on the limit of needing to be compressed to go on, so one of those little phrases of "ease on".

Front all built to a stage I could put on the wheels but I've resisted doing that. A little padding needed in places with washers without making certain parts to tight, was quite impressed that the two sides were very even in the gaps. I did need a couple more washers so picked them up on a visit to Beaulieu for the massive classic car part event.

Rear suspension built but not to the stage of being able to put wheels on.

I did get a phone call from Peter at GKD who told me there was a machining error on part of the rear uprights. A little frustrating but to be fair Peter did contact me immediately he had found the problem and had a way to correct that meant I wasn't too inconvenienced.

Pedal box and associated parts all put together a couple of holes needed a little filing but to be expected somewhere I'm sure.

A few other little jobs done.

More cleaning of old parts needed before going much further, I may being a little too fussy but nowhere near perfect in my view.

A visit to BMW will happen soon to order the new bolts to replace all the key ones I've removed in doing this, something recommended if you were maintaining the original car so this is no different.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 06, October, 2009, 07:52:02 PM
Quote from: Richard on 06, October, 2009, 07:40:37 AM
Been a long time for an update, not sure if anyone really noticed  ;)

Actually, I did :). Been wondering how you've been getting on.

Keep up the good work.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 15, October, 2009, 12:30:45 PM
Another little update.

A bit of slow progress, however a few bits coming together.
Finally got a Small Case LSD solution. Worth noting a little problem has turned into a better solution here.

The problem "The Propshaft Clinic" went bust with my prop, so now I don't have prop and it has not been modified. This has lead to GKD doing a different solution which is actually better for all future Legend 4 and 6 purchasers. The props will in future not be exchange but will be made purposefully.

One of the big advantages of the prop set up is that you'll be able to use either the small case LSD or the medium case LSD from donor cars. This means that from the E36/E46 you can source an LSD from any that had it and they are much more common in the 6 cyl cars, the fact that the medium case is slightly longer than the small is accommodated within the prop design, this leaves the half shafts being from the right source to fit, a much easier future proposition.

The items coming together in this chassis are fitting very well, and where a tiny bit of refinement is needed GKD have taken that feedback into the next chassis out the door, overall a very good near plug n play to date.

Off into the garage this weekend for a little bit more progress but hours available are under pressure from the house decorating before Christmas, something I'm sure we've all come across  ;)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 15, October, 2009, 11:22:17 PM
Its really good that your feedback will help future builders :)

Keep us posted.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 09, November, 2009, 11:27:54 AM
Nearly a month and no update :o

Hows it going Richard? Is your car destined to become a rusty pile of bits :D
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 02, December, 2009, 09:19:21 PM
Sorry, got very very busy with work, collecting more of those lovely airmiles and hotel points and doing loads of hours. On top of that been trying to get a some progress on some rooms in the house that have no heating.

That aside, I can see the end of this recent burst of activity and a space for time in the garage tinkering. Quite a few things are ready now for putting together so hopefully each hour will see a bit of progress.

Will post an update in a couple of weeks when a little burst of activity should have happened !
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 03, December, 2009, 12:02:55 AM
Rooms with no heating come first buddy. Look forward to your progress update though :)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Marc_NL on 05, December, 2009, 09:27:04 PM
Quote from: G & Toniq on 03, December, 2009, 12:02:55 AM
Rooms with no heating come first buddy. Look forward to your progress update though :)

Why? There is no need for heating in rooms when you are working in the garage  ;D ;D

Also, always ready for an update....and pictures  ;D
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 05, December, 2009, 09:56:43 PM
Quote from: Marc_NL on 05, December, 2009, 09:27:04 PM
Why? There is no need for heating in rooms when you are working in the garage  ;D ;D

Also, always ready for an update....and pictures  ;D

Haha, welcome to the forum Marc :)

Not sure Richards family would agree with you though ;)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: testingtesting on 17, December, 2009, 08:43:10 PM
Hi,  Great thread,  I'm looking at building one too but using a 3.0 m3 motor. 

Can I ask how much you paid for your LSD?  I've had a look at a snippet of the build manual and it seems very good,  especially compared to some others i've seen!

how have you found it?  Do you get good support from peter?
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 20, December, 2009, 09:30:09 PM
Hi testingtesting.

LSD's vary in cost second hand. you can very specific ones made of course and several standard special builds are available from the US.

There are 2 sizes used in E36s with the small case only being found on the 4 cyl cars and as far as I know they were an option on the 318is version so they are hard to find but typically over the last year you see them go between 175 and 325 depending on the interest. quite frequently 250 seems to be a threshold for the more popular ratio'd ones.

With your 3.0 M3 you should have an LSD already.

The 6 cyl cars had the medium sized diff and so had different length half shafts to the small case. If I recall correctly they are different again on the M3 and you need to check them for the track size on the 6 cyl Legend. If you need to swap the half shafts for those of say a 325/328 then they are typically available for about £30 each give or take a bit.

Do check with Peter on the M3 LSd / half shafts.

Have to say Peter has been very good so far on the occaisional query and discussion about things for the future on the car. He has been responsive and if he can he'll reply out of office hours as well.

the build manual is a mystery to me as we started before he'd produced one, so a few changes will be going into the original thoughts as a result of what we've been doing.

Ratio's on LSDs vary quite a lot across the BMW range and some are more desirable than others for usual BM track cars and road tweaked cars. Use the link to various calculators and spreadsheets on this site to work out the range you'd prefer to look out for. Some ratios are more readily available.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 20, December, 2009, 09:35:04 PM
To pick up on your welding question on your intro.

The welding has been pretty impressive, not quite up to the falling coin stack on the better bike chasis's  but solid enough, in a few places there has been a little welding in the way of washers fitting back cleanly but this is not a big issue. The symmetrical nature lengths and gaps have been very good.

The 6 is a slightly bigger structure in the front and like the 4 a different mix of sizes and shapes are used.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: testingtesting on 21, December, 2009, 06:13:07 PM
Hi,

Problem is the m3 diff doesn't 'hang' the same so I've got to use a none 'M' diff/drive shafts etc etc.

I've ordered a kit now, pick up march time.  Found out that e36 325i diff's are the same ratio as the 3.0 M3 one  so sorted there.  Just in the process of getting together the bits I need from a donor, Looking at £200ish for uprights/calipers(m3's are the wrong fitting)/diff/hubs etc.  For drive shafts I'll buy new ones as there £70 each new or atleast £35 from a scrap yard, with the m3 motor I'd prefer the piece of mind.

All things being well when I've sold off the bits from the m3 that I can I should have all the donor parts and the m3 engine/box/loom for about £500 tops which works out quite well for 300bhp!

Richard does seem very good on the phone and he's assured me the build manual will be finished by the time I pick my kit up.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 22, December, 2009, 08:52:02 PM
Ah, the previous model one side rear mounting plate then ?
If so, you can swap the mounting plate for one from the E36 and it will fit  :D.

I'm not sure all 325's had a slipper but sure you've found that out, yes they had same ratio as standard. The 328 / and later M3's had different ratios.

That is a good price to get that lot for !!
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: testingtesting on 26, December, 2009, 01:52:42 AM
well, ended up with a 325i (none lsd) diff
328i calipers/hubs/uprights/rear disc flange for £200.

I'm hoping when I take the m3 apart I can fit it using the 325 diff's drive flanges... I'll keep you posted.

If not I'm not too fussed and can't afford to buy a LSD for the 'normal' diff.  Roll on march!
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Marc_NL on 27, December, 2009, 06:55:09 PM
Good to read that another build is about to commence.

I have had some conversations with richard and trying to follow his build closely and will do so on yours as well  :o :o

I am spending this christmas holiday to work on my shed (alias garage) and get it prepared for serious work. Tools also coming in this week. If all goes well my plan is to start building a 7ish car (with focus on the GKD at the moment) fall next year.

Have fun with the preparations and build, I will be watching you  :P :P
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 27, December, 2009, 09:35:50 PM
Good to hear, and glad Marc you've so called "come out of the closet"  ;)
A few other builds I know of underway as well in different places, not all on public forums, which is totally fine.

Just been checking out garage heaters to make it a little more comfortable out in the garage in the coming weeks.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 27, December, 2009, 10:00:27 PM
Quote from: Marc_NL on 27, December, 2009, 06:55:09 PM
Have fun with the preparations and build, I will be watching you  :P :P

Marc, hopefully we will be watching your progress too ;)

Quote from: Richard on 27, December, 2009, 09:35:50 PM
Just been checking out garage heaters to make it a little more comfortable out in the garage in the coming weeks.

I was considering one of these http://www.machinemart.co.uk/shop/product/details/little-devil-propane-fired-space-heater/path/space-heaters-workshop-heaters

Log burners are great as well if you can fit one.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Marc_NL on 29, December, 2009, 06:51:18 PM
When a project gets started and there is progress, it will be shared ofcourse! For now it is a matter of preparation which is already a lot of work. Which kit, what philosophy of building etc. And ofcourse getting the work area ready, which is what this winter is good for.

The rules and regulations are a mess here. Recently the tax-free CO2 range is reduced to only 110g/km. This is impossible to reach with a legend 6. Also a law is being prepared to make it illegal to tune or tweak the engine  :o :o

Just a little info, probably already known, but it won't hurt to share it. Quite a few E46s (at least overhere) were fitted with a clutch-delay-valve. This, as it name impies, makes it impossible to release the clutch fast. This is greatly annoying, especially in throttled downshifts. Be sure to remove this bugger.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 29, December, 2009, 08:39:33 PM
Easy enough to source an E46 from UK Marc !  ;)
and not too far to drive it back, then build a LHD model (no need to change parts for a GKD build).

Not sure you'd want to do too much tuning to start with with the power to weight ratio you'd get compared to your road car.

Anyway a very small bit of progress today before deciding a source of heat in the garage is required !

Log burner is quite a good idea.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Marc_NL on 10, January, 2010, 05:06:50 PM
Sourcing a donor is not an issue, it will not take up much of the total cost. Getting it on the road here is the expensive part, full with ridiculous rules etc. That is no longer easy to circumvent by taking an alternative route of import or whatever...

As an indication; CO2 emission is calculated as:
CO2 = 0.078m + 0.527p + 27.035
Where m is roadready weight, p is power ik kW. Above goes for a manual petrol car. The first 110g of emission is 'free of charge'.
Simply put,  a 1063kg car (about 950kg empty weight) without an engine is subject to charge. Same for a weightless car with 157 kW engine...

Between 110 and 180 g/km the charge is E35 per gram this year, up to E 95 in 2013....
Real Madness if you ask me.

Is the garage heated now? Any progress?

I am still working on the shed, but the tools have arrived...slight progress.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: rodgling on 07, February, 2010, 12:16:10 AM
any progress...? I'm desperately trying to get all the 328 donor parts ready for when my legend chassis arrives in a couple of weeks, though I suspect I won't manage this.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: testingtesting on 13, February, 2010, 08:44:53 PM
As above, any updates?  My chassis arrives in a couple of weeks too. ;D

I've got all the donor car stripped down now too.... that was a bit of a pain in the ass!
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 19, February, 2010, 08:53:53 PM
Been away yet again, and in cold.

Will get back on this topic typing up.

Good to hear you'll getting those chassis soon(next week ?).

A few little tweaks needed for IVA Peter's let me know, seem very simple and not affecting chassis.

Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: rodgling on 20, February, 2010, 08:58:23 PM
well, i've given up on pressing out the bloody halfshafts (went out and bought a puller and a sledgehammer, but still no joy) so am taking them to a garage on Monday to get them to do it. anyone else have this problem, or did you manage to press them out OK?
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 20, February, 2010, 09:21:04 PM
They are a real pain to get out !!!

No wonder they sell those special tools for a couple hundred pounds, if you had a garage you'd need them.
£25-30 each second hand.



Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: testingtesting on 26, February, 2010, 06:33:32 PM
Any update Richard?

Had my chassis arrive so started work on mine now ;D
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 27, February, 2010, 09:45:54 PM
Excellent News !

Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 27, February, 2010, 09:50:39 PM
First catch up post.

Pedal Box, pedals.

A bit of a fiddle to get access to the bolts for the cylinders so flexi sprocket needed but not awful.
A very tight fit on bottom of cylinders to box metal, a tiny bit of filing needed.

Haven't got any issues in my notes other than that mentioned above, so went reasonably well.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Dixie on 27, February, 2010, 10:11:10 PM
How long now.  Will it be ready for the summer??
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 27, February, 2010, 10:25:12 PM
Mark, hope so, have a bit more time coming up and less travel so should be able to tinker away a bit more. Got a few goals in mind but let's see.

Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Dixie on 27, February, 2010, 10:37:06 PM
How are you getting to Stoneleigh?  Are you going with your son?  If you're on your own, I have a seat spare in the Cob??

Mark
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 27, February, 2010, 11:02:16 PM
Quote from: Dixie on 27, February, 2010, 10:37:06 PM
How are you getting to Stoneleigh?  Are you going with your son?  If you're on your own, I have a seat spare in the Cob??

Mark

Not sure yet, have yet to think about it really other than reserve the dates in my diary. Would be happy to ride shotgun if no toy to go in.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 02, March, 2010, 05:50:06 PM
Yippee - Adjusted rear uprights have arrived / collected on a drive down A303 by Peter on another Legend chassis delivery run.

Interesting to see the few changes from my experiences are incorporated into these latest ones. It is just getting a bit simpler to build with these little adjustments.

Beginning to hear some interesting experiences about IVA testing and the "interpretations" of some of the greyer areas of the text. Mostly it all sounds logical to me but then I've not got there yet.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 03, March, 2010, 08:40:48 PM
Among the house decorating I nipped to the garage and noticed I'd put in a couple of bolts the wrong way round some time ago on the front suspension, so spent a bit of time correcting, one darned fiddle, but hey bound to be a few of these self induced things as we go along.

Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 03, March, 2010, 08:44:24 PM
Got any pics to post up rich?
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 17, March, 2010, 06:22:32 PM
Must upload a few pics.

I did a financial progress check and hours spent doing things out of curiousity.

Then I thought I'd compare with GKD claims on build costs on their website, just as a point of reference.

In summary, you can definitely achieve a build for the costs GKD claim. I've spent a bit extra in places you don't need to in order to get a running car on the road but then I suppose that is the way of kit cars.

I've even managed to buy a few tools within the budgets he's quoting so that has worked out well.

A few teething issues I've had have already been altered for subsequent builders and I've even seen that myself on other deliveries to other customers, good to see customer feedback being acted upon.

Main niggle is the plasma cut panels, which take a fair amount of effort to tidy up, but so far for my purpose that has been ok to do, I suspect that laser cut panels are more expensive so that would become a trade of time to money.

Will do a little more of an update at the weekend, now it is food then off to the garage this evening for a couple of hours of tinkering on the engine  ;)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 22, March, 2010, 11:04:35 PM
Been doing a few little checks and double checks.

Little amendment made to the T pieces on brake lines, I did not have them on nyloc or locktited so have amended that.

Double checked the cable run tie spacing and all at 200mm or below so that appears to be in good shape.

Experiments on the panels coming along, totally convinced this will not compare to the others in the club in quality of finish but an interesting learning curve. Certainly the paint finish is very proportional to the preparation put in.

Been keeping a log of the torque used on the various nuts/ bolts, using the ones from the BMW manual for those re-joined parts.

Still need to post a few of those pics.


Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 22, March, 2010, 11:20:52 PM
Quote from: Richard on 22, March, 2010, 11:04:35 PM
Still need to post a few of those pics.

Yep, people might start thinking you've made it all up Rich ;)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 23, March, 2010, 10:10:06 PM

(http://s1.postimage.org/qUg2r.jpg) (http://www.postimage.org/image.php?v=gxqUg2r)

rear T piece on brake lines, locktited underneath, another hole drilled as an option while prop out of the way, may well be bunged later, avoiding any concern of rub/wear in future., prop still out for a couple more days, diff been mostly cleaned up but long way from perfect.

(http://s3.postimage.org/db1OJ.jpg) (http://www.postimage.org/image.php?v=Pqdb1OJ)

without disk/caliper but showing cover on steering, not heat shrunk to meet requirements, ties to be tidied still.

boys had various wheels on rear today checking the options.

trial paint attempts coming along but still amateurish.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: rodgling on 23, March, 2010, 11:01:32 PM
Richard, I don't want to alarm you, but your steering rack appears to be held together with cable ties...
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 24, March, 2010, 08:01:14 AM
Quote from: rodgling on 23, March, 2010, 11:01:32 PM
Richard, I don't want to alarm you, but your steering rack appears to be held together with cable ties...

Because it is  ;D

I leave the ties long until the end, this way you can open them up with a tiny screwdriver if you need to adjust things. The ties will have to be off for the IVA test as it needs to be accessed to inspect what is under it, this then means the fit has to be tight enough to hold in place, so some form of tape wrapped to give a snug fit will be in order, added to list of items to check at end.

The nut under the shroud would be met by the sphere used in IVA so needs to be covered but from what others have done the heat shrinked covers haven't been accepted.

I'm trying to as I go check things against my reading of IVA regs and the hints tips from Peter(GKD) as well as others.

Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 24, March, 2010, 11:16:12 PM
Looks like some good progress there Rich, keep up the good work :)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 27, March, 2010, 08:54:22 PM

(http://s2.postimage.org/Aamui.jpg) (http://www.postimage.org/image.php?v=TsAamui)

shed is now a temp paint booth.

experiments in painting, not yet a Master  ;)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: rodgling on 27, March, 2010, 09:00:28 PM
You've gone for a white one as well then? Good choice. I reckon I'll probably leave the painting for a while - I want to crack on with the suspension bits first.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 28, March, 2010, 11:00:55 AM
having some temporary trouble posting a pic, but tidyimg up exhuast manifold to have nicely lined up holes and smooth edges, before fitting.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 28, March, 2010, 11:02:59 AM

(http://s4.postimage.org/afYS9.jpg) (http://www.postimage.org/image.php?v=aVafYS9)

there you go, some work to do as you can see.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Bulldog Bri on 28, March, 2010, 08:50:54 PM
Looks good Rich...

8)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: testingtesting on 29, March, 2010, 09:26:11 AM
Looks good :D

Do any of the panels need bending before fitting?  Wouldn't want your paint to splinter.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 29, March, 2010, 10:18:24 AM
Those that are painted are already bent into the shapes needed, a bit of an trial of paint shades and techniques on relatively harmless panels, not 100% happy but getting better at it.

The exterior panels on the car may well have to be painted in situ given the jiggle to get them back on, not quite decided how I'll tackle those just yet, all holes drilled and trial fitted, will have to see how the interior trial ones get on.

Tidying up the exhaust manifold is more time consuming than I thought it would be to get the curves and smoothness done, still slowly but surely progress is made.

Replacing the O2 sensor with a new one when it is fitted, although in a future iteration of the engine and its management that might turn out to be not so needed, but for now it is to be replaced.

Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: rodgling on 29, March, 2010, 10:54:26 AM
So you're painting the interior panels as well then? I had planned to leave those unpainted, will have to see how yours turn out.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 29, March, 2010, 11:04:27 AM
Quote from: rodgling on 29, March, 2010, 10:54:26 AM
So you're painting the interior panels as well then? I had planned to leave those unpainted, will have to see how yours turn out.

It was a way of trial painting in a place it didn't matter too much.
I did try polishing them up, very hard work and you need a high degree of dedication and a polisher tool.
Another option was to sand to leave a brushed aluminium finish.
A degree of "fettling" required, had a couple of welds that weren't ground down before powderder coating so had some touching up to do there.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: rodgling on 29, March, 2010, 11:09:40 AM
Yes, I had the same issue with welds sticking out in a few places. I just modified the panels to go around the welds as I didn't fancy potentially weakening the chassis by grinding away any weld. Fortunately this was only necessary in places which won't be very obvious.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 01, April, 2010, 09:19:12 AM
A few more items being tidied up before fitting

(http://s2.postimage.org/NAbwA.jpg) (http://www.postimage.org/image.php?v=TsNAbwA)

A little more tidying for these large washers and on they will go.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 11, April, 2010, 08:18:56 AM
Stuck waiting for wiring loom  :(

If gardening chores among others permit will spruce a bit more of a panel up and do a phone pic walk.

Apart from that not much to do without wires.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: testingtesting on 11, April, 2010, 09:37:27 AM
have you put your steering system together yet?  If so any pics?   ;)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 11, April, 2010, 06:29:28 PM
Quote from: testingtesting on 11, April, 2010, 09:37:27 AM
have you put your steering system together yet?  If so any pics?   ;)

In pieces to go back and polish inside exhuast manifold, filling time waiting, was going to leave it a bit rough but should be able to polish it over next couple of evenings and then reassemble.

Can understand you asking a darn fiddle, which chassis do you have as new ones have an easier guide for alignment on it.

Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: testingtesting on 11, April, 2010, 10:19:00 PM
got a 6 chassis but the manual doesnt seem to make sense.... hoping to get some pics some how!!
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 12, April, 2010, 03:19:31 PM
Quote from: testingtesting on 11, April, 2010, 10:19:00 PM
got a 6 chassis but the manual doesnt seem to make sense.... hoping to get some pics some how!!

Will put it back together by Friday as have some time Wednesday eve to polish manifold, then I'll pic it for you. May alter the height a bit at some point, but not for now. Then will send Peter an instruction update.  ;)

Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: testingtesting on 12, April, 2010, 10:11:57 PM
Good man :D

Can I drop you a pm so you can email some pics direct?
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 12, April, 2010, 10:43:08 PM
Quote from: testingtesting on 12, April, 2010, 10:11:57 PM
Good man :D

Can I drop you a pm so you can email some pics direct?

Of course  :D
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: rodgling on 12, April, 2010, 10:53:18 PM
Or just post pics here, I'd certainly like to see how it's going, even if I haven't got stuck with my steering yet. Like you, I'm now stuck waiting for parts to arrive before I can progress any further. I suppose that means I'm making progress...
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 12, April, 2010, 11:31:26 PM
Quote from: rodgling on 12, April, 2010, 10:53:18 PM
Or just post pics here, I'd certainly like to see how it's going, even if I haven't got stuck with my steering yet. Like you, I'm now stuck waiting for parts to arrive before I can progress any further. I suppose that means I'm making progress...

Yeah, get them pics up Rich :)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: testingtesting on 13, April, 2010, 10:37:01 AM
of course on here is fine,  its just if I get some direct I can enlarge them better for my dodgy eyesight!  :P
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Marc_NL on 16, April, 2010, 06:42:08 PM
Hey Guys,

Good to hear of progress here and there. Any online (b)logs with pics? I just returned from some trips and time might just be opening up to allow me to get on with the gathering of intelligence (in both aspects of the word :D) and preparations.

Keep them posts coming!
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 17, April, 2010, 07:27:28 AM
(http://s4.postimage.org/ie2vi.jpg) (http://www.postimage.org/image.php?v=aVie2vi)

No wiring loom yet  >:(

Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 17, April, 2010, 08:21:05 AM
 
(http://s1.postimage.org/OYk_i.jpg) (http://www.postimage.org/image.php?v=gxOYk_i)



(http://s4.postimage.org/ihw_S.jpg) (http://www.postimage.org/image.php?v=aVihw_S)



(http://s2.postimage.org/ItRyJ.jpg) (http://www.postimage.org/image.php?v=TsItRyJ)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Marc_NL on 17, April, 2010, 04:21:13 PM
Richard, looking at your images it seems you are progressing well. And at this stage, you might just be able to answer a question I have.

Is it possible to route the exhaust through the tunnel? I am not really a sidepipe fan and at this moment I would prefer rear exhaust, M3 style. Just wondering...quite hard to judge by the photo, but it looks like there is some space overthere... Impossible to judge if it would clear the transmission...
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 17, April, 2010, 05:54:42 PM
Quote from: Marc_NL on 17, April, 2010, 04:21:13 PM
Richard, looking at your images it seems you are progressing well. And at this stage, you might just be able to answer a question I have.

Is it possible to route the exhaust through the tunnel? I am not really a sidepipe fan and at this moment I would prefer rear exhaust, M3 style. Just wondering...quite hard to judge by the photo, but it looks like there is some space overthere... Impossible to judge if it would clear the transmission...

Doubtful, easy enough to do a quick mock up try with other pipe of similar size to exhaust I have, will try and get to it this week, unlikely to be this weekend though.

Issue will be getting a route past transmission and keeping ground clearance, once at rear  options open up a bit but still going to be a tad tricky for box location/ angle. Instant reaction would be not without a few critical changes, the GKD Evolution still has exhaust on sides but enclosed, for you of course it would be your passenger's problem anyway  ;D

Hope your travels have been good again.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Marc_NL on 20, April, 2010, 08:29:01 PM
Thanks, it would be great if you could give it a look / try !

The trips were great, been able to attach some two weeks of holiday to my South-Africa trip...Easily back in time before the soccer starts overthere  :P
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 20, April, 2010, 10:03:14 PM
Had a pipe fiddle earlier, upshot is that is not going to happen without going under chassis then you risk bottoming out on the 4 cyl chassis, now with the 6 cyl it rides higher for several reasons but mostly because of the height of the engine, this means it may work on 6 cyl model and not be lowest point, then it would be silencer location fun. Certainly able to reduce the sharp bends out quite nicely.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: testingtesting on 17, May, 2010, 04:20:19 PM
Hi Richard,  managed to make any more progress yet?  Can't be far away from IVA now ;D
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 25, May, 2010, 12:08:25 PM
OK a short update and then a few pics later in week when back to garage.

Most of wiring in place now.

Painting / sanding routine continues my education on painting.

Engine started with key in ignition and the fuel coming from the fuel tank, not first turn as a slight ignition wiring error, but quickly altered and noise was heard of a running engine.

Pics will follow and a more complete update.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: testingtesting on 28, May, 2010, 10:48:54 PM
Good man,  keep it coming :D
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 28, May, 2010, 11:32:11 PM
Quote from: testingtesting on 28, May, 2010, 10:48:54 PM
Good man,  keep it coming :D

Agreed, get them pics up Rich.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 29, June, 2010, 06:20:20 PM
I owe a really big update here.

been a bit run ragged with everything going on.

current status is IVA forms off, paid for and test booked.

should have time next week to start catch-up on posts and pics..

Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 21, July, 2010, 08:55:44 AM
IVA Number 1 has now been completed

You guessed it a fail on a short list of things i.e. < 1 page fully typed up with VOSA form headers.

2 items with fog light - I'd forgotten to wire the tell tale on the dash for it and the surface of the fog lamp was not vertical.

Bolts inside the wheel not covered, I thought this area was exempt but it seems another "grey area of interpretation".

Hand brake not enough spare travel.

Projection of edge of scuttle on top of side rail and nuts above not covered with IVA covers (although below scuttle they were).

and a couple of other easy alter items.

So quite a short list, fixes underway so hope to get a retest quite quickly.

The guy who did it was friendly and professional and quite pleased to see a non-Pinto powered toy.

I had an uneventful 60 odd mile round trip to do it, so the car had a bit of use for the first time not on the drive / garage.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Bulldog Bri on 21, July, 2010, 09:01:44 AM
Sounds not to bad Rich, well done.

Could be getting mine set for IVA soon nice little policy maturing soon  :D (so any help please as I hate form filling)

8)

Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 21, July, 2010, 10:14:45 AM
Quote from: bulldog bri on 21, July, 2010, 09:01:44 AM
Sounds not to bad Rich, well done.

Could be getting mine set for IVA soon nice little policy maturing soon  :D (so any help please as I hate form filling)

8)

Emailed you the forms part filled in for you. I did ask a few "what if" questions based on what I've seen of your car so will happily come up and walk around and see if we can get your list smaller than mine  ;D
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 21, July, 2010, 12:16:42 PM
Well done Rich. We should be seeing you on the road soon :)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: YellaBelly on 22, July, 2010, 04:23:47 AM
Nice one Rich. Don't suppose you have any pictures of the area of the scuttle that failed?

JB
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: rodgling on 23, July, 2010, 06:52:26 PM
Sounds like a reasonably good result - well done. Should go through with no problems once you get those sorted, fingers crossed.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Hairy Santa on 23, July, 2010, 10:54:21 PM
Hi Rich,

Sound like you will be joining us on the road in the very near future

Well done that man

see you soon

Pete

hope the Australia connection is still there  :)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 24, July, 2010, 08:07:54 PM
Pete,   yes Aussie connection still there, had a reassurance email couple of days ago, he's looking to see how he can make them for the future then will post on.

Will take a few pics and post some explanations up.  Will also do my IVA / DVLA process experience write-up sometime when done (have my usual notes on things as I go along ready todate).

Used up most of my car time this morning with Bri playing IVA inspector on his vehicles so ran out of car time for most of this weekend.   JB - if you'd like a look over before you go in for IVA I'd be happy to pop over and spend some time being picky  ;D.

Still a couple of fixes already done and in place so will book retest on Monday in their office hours. Have the registration paperwork nearly done so will be making a packed lunch and going for a DVLA office queue at some point soon I hope.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Bulldog Bri on 24, July, 2010, 09:14:55 PM
Big thanks Rich for coming over this morning, it good to get someone elses opinion as they sometimes see stuff that you so easily over look as your looking at it so much.

Have started tidying up the wiring as suggested (and knew I had to do)  though not to such an extent.

Sorry I took up all your car play time though.

Cheers again

8)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 04, March, 2011, 05:53:19 PM
Lots to catch up on so here is a very brief update.

Car painted.
COP conversion done.
IVA passed.

Registration not done yet.

(http://i1117.photobucket.com/albums/k581/RicheBMW/LegendM42.jpg)

(http://i1117.photobucket.com/albums/k581/RicheBMW/LegendwithM42.jpg)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: 'The Gaffer' on 04, March, 2011, 06:45:39 PM
Looks great, like the colour.

Looking forward to a few more pics and words as well ;D
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Denzle on 04, March, 2011, 07:28:25 PM
   Looks nice..... 8)

Can you show us a couple of full blown pics of the lump and the car.... ;)

                                                                       Cheers....Denzle.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: stupott901 on 04, March, 2011, 07:50:39 PM
looks great and the colour is cool as well so youll be out and about soon ?
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Bulldog Bri on 05, March, 2011, 04:15:53 PM
Looking really good there Rich, well done. Haven't moved at all on mine now for months, just can't find the time/money of late  :'( still also struggling on the Merlin and Gentry. Will get there one day though  ::)

Looking forward to seeing it for real

8)
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Quarrycars on 05, March, 2011, 04:42:55 PM
Great job Rich, really neat engine instalation.  Great write up too, I just went back and reread all 11 pages!
Re. the the COP conversion, I assume the engine originaly had a distributor, is the conversion an aftermarket kit?
Keep up the great work, cheerz, JT
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: peetee on 05, March, 2011, 07:26:11 PM
What a lovely immaculate looking car
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: David H on 05, March, 2011, 08:16:53 PM
very tidy. looking forward to seeing it around
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 05, March, 2011, 08:52:55 PM
COP conversion:
A few observations.
This was a bit of story in its own, so will tell a few highlights and items for those that follow. Basic gist is now this has been made really simple as GKD will be offering COP conversion kits for the later M42 and therefore M44 BMW 4 cyl engines. (Don't tell anyone but this hadn't occured to him before)  ;)

The E30 318is has long had quite a fan base and several people have produced their own COP conversion plate for these models, same engine M42. Then in the E36 use of that engine BMW changed the wiring to make it less simple, this happened before my engine so I had the later wiring head scratching conundrum.

So, got hold of a machined plate for the earlier coil pack from an E30 enthusiast not far from me, there are several guys around the world where you can get them from, basically all pretty similar.
Of course as with so many BMW parts several other 6 cyl engines provide just the right parts for the COP part, so wiring was then the challenge.
It took Peter of GKD and I a little while to track the right connectors to make this work tidily, and while doing so he came up with a neater idea for the plate for this conversion so the connector became a simple unplug and replug/ locked into an extension to the plate and then connected to a made up mimi loom, all now very neat. Another little spacer search needed to get and keep right position.

Quite genuinely this was put together put on engine and ran first time really cleanly  ;D

So, now a GKD product offering that will work on the later M42 engines, and of course even simpler for the earlier ones still.

Will get a few pics when I get a chance but be a week. Tidies up the engine bay a bit and of course should be a bit improved as well.


Had the O2 sensor give up so a new one on the way now. But MOT done and within emissions as well, tyre change will be needed soon, although somewhat amusingly I have some Michelin ICE winter tyres that fit these wheels, just need some snow and ice now.

Still quite a list of jobs to do, no surprise eh  ;D



Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Quarrycars on 06, March, 2011, 01:21:02 AM
OK, I hadn't realised that this was originally DI with remote coils (excuse my ignorance :-[)  I was wondering if someone did a distributor to COP conversion, but thinking about it that would be tricky as the pickup in a distributer doesn't 'know' which plug it is triggering as that's determined by the rotor.  With a DI system fireing cyl(s) are determined by the flywheel reluctor.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 02, April, 2012, 10:59:05 AM
Well, ahem, long time since posted anything anywhere.

Just a short update.

A little alteration to the car is well underway and should be ready for Deitling show at the weekend, the car will also be at Stoneleigh this year.

Just gone over with Peter at GKD the various changes since the original version, quite a few having come from what we found. Truly a lot of little tweaks to make it a relatively simple build now e.g.

A little extra power and torque added too, sssccccchhhhhh  ;)  still 4 cal though

May sell it but if not expect to see it with Thomas driving at TrackDevelopments in May.
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: T1G UP on 16, May, 2012, 10:16:12 PM
whats the cost of the kit?

i found this site by looking for a kit to put my m3 running gear in!

ny other kits take bmw running gear???

Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Richard on 16, May, 2012, 11:47:13 PM
Quote from: T1G UP on 16, May, 2012, 10:16:12 PM
whats the cost of the kit?

i found this site by looking for a kit to put my m3 running gear in!

ny other kits take bmw running gear???

Kit costs vary and are a bit different now from when I started, prices on the GKD website with the options so best to get latest from there.

All will take 6cyl engines and as long as your M3 is not the newer v8 it will fit, work and is proven to do so.

Other kits are beginning to take the BMW 6 cyls, Marlin of old did but re-used BMW suspension and very little else, also a heavier car.
As far as I know JBA have started to use the 4 cal BMW engines and Dax have a non-running demo using a 6 cyl engine from the newer E46.
Faroux are going BMW power route but I've not heard of any builders.
Some lambo copy kits use the V12 BMW engine.
More will appear but GKD have been doing it longer and as a result have learnt a lot about using the BMW components in kit cars.
The kits now are also very much easier to build than before and are being regularly improved.

All GKD kits take the M3 engine E36 and E46, among other BMW engines and re-use a lot of BMW parts.

With M3 power you have a lot of torque and power per tonne without any specialist tuning, do note the slightly nutty 6 cyl exhaust as seen on Jason's car is not the GKD std one which is much tidier in my opinion. I think Jason was short shifting and still 3.1 to 62mph and just over 7 to 100, so nippy enough in standard no tune form !
Title: Re: My GKD Legend Kit Car Build - May 2009 until ...
Post by: Hairy Santa on 17, May, 2012, 10:05:17 AM
saw the Dax BMW up on the stand at Stoneiegh

looked to be a nice build but a lot of engine cramed in a very small space - be interesting to work on I think  ;)