Wednesday June 1, 2005
After a long (work filled) winter hiatus the ULTIMA build resumes. The first day of the build (June 1, 2005) is a bust. I run around trying to pick up where I left off in October 2004. Everything has been packed away for safekeeping and I cannot remember where anything is anymore. I also cannot remember what I should be doing next. I spend the day moving and opening boxes, organizing the garage and looking at the unfinished ULTIMA without any real progress. At the end of the day I am worried that I may never finish this build.
Thursday June 2, 2005
I get up early and resolve to do some work on the ULTIMA today regardless of build order - just so that I can point at something and say that I did some 'busy' work.
I find the #2 gauge welding cable that I purchased last year to ensure that I had a direct ground to the engine from the battery - I was told by several auto electricians that a good reliable ground is mandatory for any racecar - I was also told not to rely solely on the chassis for a good ground. I proceed to fill the cable lugs with solder and heat one at time with a propane torch until it is liquefied. The bare copper prepared end of the cable is then squeezed into the open lug and liquid solder until it seats and is secure. I attach it to the car alongside the positive factory cable and run it to the engine bay.
I next turn my attention to the luggage containers that I pre-fitted last year but did not rivet onto the chassis. I examine the location of the cooling system pipes and the clearances between them and the luggage containers and decide to relocate them so that they clear the luggage containers better in order to thermally insulate them from the containers (and the car). I also want to ensure that they are isolated from the chassis to prevent any rubbing or chafing failures since they will be captive within their respective side pods and impossible to service, if that happens. I drill out the bracket rivets and spend a very long time relocating - test fitting - relocating until I am satisfied that they are optimally positioned before I finally secure them back onto the chassis. I also fashion an insulated jacket for them from the aluminized material that I used for the thermal and acoustic insulation elsewhere on the car.
Friday June 3, 2005
I start work on adding an additional seven wire "future options" harness to the chassis. The harness consists of three12 gauge and four 18 gauge wires - this should allow a lot of future flexibility for additional circuitry should the need arise. Bear in mind that I already have four separate relay activated circuits hooked to the accessory side of the ignition switch as a further backup for new accessories.
I spend the rest of the day picking up supplies from various places in the city - rivets, a new small band saw for cutting wood and metal, (an excellent, not to be missed deal from a vendor that I know) two AN 12 aluminum weld bungs for the fuel tanks etc.
Saturday June 4, 2005
I leave home at 7:00AM, both fuel tanks in hand, to meet a very skilled welder who has been highly recommended. He will TIG weld the AN 12 weld bungs to the tanks so that I can link them and fill the ULTIMA with gas from either side. This is an idea that Ed Eingals suggested in his build CD which is an excellent source of build information if you are thinking of buying or are in the process of building an ULTIMA.
I leave the tanks with him hoping to pick the completed tanks up, some time in the next few days - I am pleasantly surprised when he calls me as I get back home, to say that he decided to work on them immediately and that they are ready for pick-up.
I go back and pick them up; the workmanship is superb and I am happy to pay him for his services.
My son joins me later and we drill, skin pin, bond and rivet the left (driver's) side luggage container to the chassis. We elect to push the container towards the front of the car and install a 20mm square aluminum spacer to fill the resulting gap at the rear chassis outrigger frame.
Sunday June 5, 2005
I start early and secure the right (passenger) side luggage container to the chassis. I spend the rest of the morning insulating and installing the AC and Heater hoses from the HVAC unit through the luggage containers and into the engine bay.
My son joins me later and installs the four pull handles and cables for the front and rear latches for the body sections.
