The second Build of F351 PLL

As you may have read elsewhere F351 PLL died drastically after only 3 corners at Binbrook Lightning stages 1/9/02 after hitting a bail head on at about 80+ and then sliding sideways into another bail. There wasn't a lot left of the bails! The O/S front wing had gone along with the inner wing, the roof was up 1.5 inches and the drivers door back the O/S 1/4 panel was splitting away from the roof and the front screen didn't fit properly any more. The N/S door, B post and rear 1/4 was in to the cage and the boot floor had moved about 1" with the rear arch about 4" from the vertical. This is what we had to go through to get ready for the Rally Yorkshire in 3 weeks!

A Shell was bought prepared as I didn't have the time to put into this project. The budget is very tight using most of my piggy bank. As it turns out the shell was very well prepared in the strength, welding and cage department. All the glass, bonnet, boot, doors and lights were in situe along with the dash and wiring. This was the first problem as the wiring had to come out and I decided to strip the interior completely to get this right. I will have the gear box apart as on the last 2 rallies it seemed to drop out of 3rd occasionally. Whilst I'm there a new clutch plate will go in. (again) I also bought a complete rose jointed gear linkage with the shell.

All work will be done after main employment. Around 5.00pm.

Sunday 8th September 2002
As the build was being done at a friends garage I had to have it rolling pretty quick so the first thing that went in was the rear beam. (Had to take it out first) Whilst I was doing this Jim was ripping out all the wires.(4 hours)

Monday 9th
Raining, no roof on the shed I'm working in where the broken shell is and I've got to get the front x-member and suspension off. I donned my motorcycle waterproofs and got stuck in. After an hour or so the front end was wheeled into the dry garage and I fitted it to the new shell. Amazing what nasty conditions can do for your work speed. Can't remember who it was but Gant, Taylor or Fayol, eat your heart out. Any way another hour or so passed and the complete front suspension was on. Even had time to fit the steering column! (4 hours)

Picture quality degraded due to batteries going in my digi camera.

Tea boy(joke), Dave, on the left and Andy, owner of the garage (AG Motor Services in Leeds) in the yellow. Without his help I would have found this project very difficult in deed.

Tuesday 10th

The engine and gearbox was taken out and fresh damage was found on the O/S front chassis leg. It resembled a dogs leg and was very close to the cam cover of the engine! (2 hours)

Wednesday 11th
The gearbox was split off the engine, stripped and cleaned.(2 hours)

Thursday 12th
The box was built using a new 4.4:1 Crown wheel and pinion (output shaft) and a replaced 3rd speed selector. Whilst there I replaced an output shaft bearing and changed the selector shaft as it was showing signs of wear. One of the inner bushes on the output shaft gears had picked up some instant gasket in the lube holes so this time when I built it I used the gasket sparingly. Hope it doesn't leak. (3 hours)

Friday 13th
Don't know if I should work on it today? I fitted the rose jointed gear linkage and measured up for some aircraft quality brake hose. (1 hour)

Saturday 14th
This was a good full day. I stripped out the dash, heater and wiring from the old shell, stripped out the dash,heater and wiring from the new shell and fitted the old dash, heater and wiring to the new shell. The bias brake box was removed and fitted to the new shell. Most of the old shell has been stripped now of ancillaries such as battery, fire extinguishers, cage, navigators footrest, etc..(6 hours)

Sunday 15th
Due to too many beers last night not much got done today. I went in, got the grinder out, had a play and developed a headache so left. (1 hour)

Monday 16th
Engine in! But then out again cos I didn't assemble the gear box correctly. Put the selector arm in the wrong way! Fixed it now though.(As the old saying goes, "more haste less speed!") (3 hours)

Tuesday 17th
Ground out the seat mounting bars this morning ready for the new stuff. Wired part of the engine up. I was at work until 9:00 pm tonight. I really don't know if I'll have enough time for a completion date of 26/09! (2 hours)

Wednesday 18th
At work from 9.00 til 9.00 so nowt done.

Thursday 19th
Managed to get all the seat frame work in tonight and a lick of paint to finish it off. Still a long way to go though. (2 hours)

Friday 20th
It looks like its coming together and I can see the light at the end of the tunnel. (its a train coming the other way!) Worked 6 hours on it and most of the engine is wired up, the belt hooks are in and the radiator brackets made and fitted.

                                             Radiator in.                             Dave(Jimmy Somerville lookalike) Teaboy takes a piccie of Andy,                                                                                 and I'm in the background trying to look like I'm working!

Saturday 21st
Where do 7 hours go? Non stop working has seen the lights wired, more engine wiring connected, front suspension changed for forest, exhaust downpipe fitted but won't allow the bottom engine mount to fit, drive shafts fitted, battery and box fitted behind the seat rails and the front wing in paint.

Sunday 22nd
I fitted my new wing and painted the side trims. Worked out the petrol pipe route and tried a seat in. It fits.(3 hours)

Monday 23rd
Rear brake lines made and fitted, N/S trims painted and fitted.(2 hours)

Tuesday 24th
Time? He's waiting in the wings, He speaks of senseless things, etc. I just havent got enough of it. Fitted my new tyres today but one came with a patch already in place! I've been assured by the manufacturer that it will be OK at 120mph through the forests! Front and rear brakes are all plumbed in and I've got a radiator and oil cooler. My seat is in and all the lines are clipped into place. Just leaves alot now. (4 hours)

Wednesday 25th
I work 9:00 til 9:00 on Wednesdays so didn't get anything done but Jim Plevey went in for me and continued wiring and fitting things. I wont know exactly what til tomorrow night.

Thursday 26th
Engine running! Exhuast on, full of fluids. Just needs the front brake pipes fitting properly, bleeding, screen, seats, belts, wheels, front bumper, drivers extinguisher, dash back in again, navigators footrest, sump guard, and a few ancillaries wired in to complete. It looks like I may be ready for Saturday. (scrutineering) (3 hours)

Friday 27th
Its 12:00 am after another 7 hours and its completed bar a couple of minor things for the morning; a nut or two, a little wiring for the fan and horn, some sealer, roll cage padding, Oh, and tax, but I've lost my log book! Thanks to Andy and Jim for their help today.

Saturday 28th
Finished? As far as any competition car can be. Through scrutineering and signed on for tomorrows event. Thanks to all that helped me to get the car ready in time. (Just)

The End.