Build Diary

12/2004
Finished the side and rear panels.
Skinned the scuttle.
Attached the rear fenders.
Making housings for the rear lights.
7/2004
Started work on the aluminium body panels.
6/2004
Switched to dual master brake system with a balance bar (added to stock pedal).
New firewall for brake masters, with additional stiffness.
Plumbed the rear brake lines.
Prepared some notes "Using a CAD Program to Analyze Your Suspension" for myself, maybe useful to others.
Many, many brackets and fittings...
Bottom 18g panels.
Rivnuts and tabs for scuttle. .
4/2004
Fit roll over bar.
Analysed braking system and redesigned - $$$ :(. See MikesBrakes.xls.
Got the car back on it's paws to take some weights and measurements (mainly for my braking system analysis).
Made room for the speedometer cable.
Added an extra diagonal in the engine bay.
12/2003
Modified rear suspension for compatability with rod ends.
Mounted radiator.
Sorted parking (emergency) brake.
Remade the fuel tank using a slightly modified design.
Plumbed up the fuel system.
Fitted rear seat panel
Switched to an MR2 intake manifold.
Successfully wired up the engine and instruments. The engine runs!
Added seat harness mounts.
Switched to Previa uprights for the front suspension.
Did some analysis of the book suspension, the modified GTS strut suspension, and the Previa upright geometries here Locost Front Suspension Geometry.
Some new pictures from Phil in his gallery, and a couple of new ones of Bob in Bob's Gallery at the "British Car Day" in Bronte (courtesy of Phil who was there as well).
Some new shots in Mike Law's Gallery at a monthly(!) locost meet down under.
11/2002
Some updates to the Downloads drawings. Add gif versions for anyone without access to a CAD program. New drawing of lower ball joint mount design using a screw in ball joint.
I've used a CAD to draw up Bob's inboard shock design from his paper drawings, you can read all about it and download them here: Bob's Locost Drawings.
Got some pictures from my buddy Mike Laws, check out the really fine work he's doing on the fleet of Locosts he and his mates are building in Mike Laws Gallery.
Still working on the wiring.
Picked up a FWD version of the TVIS intake manifold. The throttle body is mounted on the rear of this version, which may give more room under the bonnet, or at least reduce the size of the blister that will be required. Details soon.
Picked up a rad and electric fan assembly from the wreckers that fits really well. In the process of fitting it now. Details and pictures soon.
9/2002
He's finished, and I got a ride in Bob's Locost. Check it out for comments and inspiration to go along with the great photo gallery.
Still working on the wiring.
Finished upgrading suspension with the new screw in lower ball joints.
Updated information on How To Register rebuilt cars in Ontario, including some links to online government regulations.
7/2002
Moved to new digs. Nice, more room, still trying to get settled. The move took place in the rain, breaking my heart and causing some rust, but that's life. I'm really thankful to Bob for helping me out, I wasn't sure what I was going to do till he offered the use of a trailer.

Lowered the engine another 1", see Drive Train Tips.
Started sorting out wiring, see Electrical System.
Redesigned front lower ball joints, see Front Suspension.
7/2001
Strengthened lower front control arms.
Mounted steering column and new steering wheel.
Built the Scuttle frame and prototype Dash Board.
Setup the Brakes.
Purchased fiberglass fromCMC (Fiberglass Gallery) , mounted theNosecone.
Spent some time with Bob Macleod, who's putting together a really nice locost.
Minor update to the information on registering home built automobiles.
New format for the Photo Gallery.
3/2001-6/2001
Project on hold.
2/2001
Welding fuel tank, nearing completion.
1/2001
Working on the fuel tank.
Replaced rear trailing arm bushes with LH threaded rod ends.
Added a new Downloads section for access to my turbocad drawings.
12/2000
Installed the steering column support ball joint. See also the steering section.
New roll bar from Bicknell Racking Products in St Catherines.
Finishing up strut caps.
Picked up fixing hardware, listed bolts used in new parts section.
11/2000
Sorted out the steering - the car can be steered!
Visited Phil's garage and Jim's shop
Added some discussion on the what, why and how of my hardboard nosecone buck.
Added some additional pointers on designing suspension based on Mcpherson strut conversions.
Added a section about my coil over shock setup to the suspension section.
Started working on the braking system.
10/2000
Built buck for nosecone from hardboard. Attempted to form aluminum for nosecone, not much success (I desperately need shrinking tools, $$$).
Aluminum sheet metalwelding (O/A) has progressed well, I believe I have developed enough skill to construct my own fuel tank.
Added some new pictures to the site, and an image gallery so you can find them.
Put some rustproofing primer on the bare metal - there's some mild surface rust forming. I just used some tremclade red metal oxide primer.
9/2000
Added Phil's alternative lower control arm design to the suspension section.
Continuing to work on my aluminum welding skills, still debating hand formed aluminum bodywork over the purchase of a fiberglass set. Depends a lot on how good the front cycle fender turns out and whether I can design and build a good looking nose cone...
8/2000
Welding table and sheet metal brake completed, they both work a treat and make my work area that much more pleasant!
Finished pedal box design.
Working on an aluminum front cycle style fender prototype.
7/2000
Designed pedal box
Finished positioning pedals and steering column
Building new welding table, sheet metal brake
6/2000
Positioned and fully welded shock brackets
Finished positioning steering rack
Started positioning pedals and steering column
5/21/2000
Cut, fit steel transmission and footwell panels.
5/13/2000
Cut filler gussets for panhard rod and shock brackets. Cut panhard rod to size, fit threaded rod inserts.
4/29/2000-4/30/2000
Received shocks, setup the rear axle and chassis shock brackets (tacked in place), panhard rod brackets. Cut down and rethreaded (used) GTS tie rod ends, and roughly positioned the steering rack.
4/2000
Cut off original rear suspension brackets, replaced with brackets attached at the front of the axle. Cut paper templates for the inner panels (16g steel). Welded in rear suspension outer panels. Ordered shocks from Aldan Eagle - 4 of AS656.
3/2000
Cut, flipped and re-welded steering arms on front uprights. Cut out rear suspension panels, rear shock gusset. Modified the rear suspension bracket to fit the GTS disk brakes.
1/30/2000
Cleaned up floor welds, fit Z member, fiddled with axle to determine bracket mods needed to fit brakes, where to position Z, and panhard rod brackets. Between OT and the temperature, tough to get into the garage. Picked up a propane heater, which helps.
1/22/2000
Visited Dennis at his workshop, was duly inspired by his car, which is coming along very well!
1/2/2000
Finished welding in floor panels
12/30/1999
Finally got time to pick up CO2/Arg refill - only open during working hours, so it's tough to get there...
12/4/1999
Floor panels tacked in place (then ran out of CO2/Arg).
11/1999
McPherson strut caps ready
Front struts modified
Suspension alignment checked
Designing steering
10/1999
Engine in place on engine mounts
Tranny in place on cross member
Drive Shaft modified
Rear suspension bracket in place
Rear Axle fitted
9/1999
Suspension brackets in place
8/1999
Transmission Tunnel tacked into place
Finish welds for chassis members so far
6/1999
Front Suspension designed
2/1999
Bottom chassis rails tacked in place
L Assembly welded
Top chassis rails tacked
Chassis top and bottom tacked
12/1998
Build table built and marked
11/1998
Donor (GTS) purchased, stripped, hauled away
6/1998ish
began search for project.
found Peter Dunn's site, 7's link, etc.
article in Toronto Star - Build Your Own Sports Car for £250
select donor (started with MGB, later switched to Corolla GTS)