Welcome to May 2008
Having been involved in supplying the kit car / motor sport industry for some length of time and attending various kit car shows up and down the country, we decided that we would take the plunge and take on a project to build our own kit car.
Surrounded by many a fantastic vehicle whilst exhibiting at Exeter, Stoneleigh and many more, we had the task of deciding which kit would be best to build, give us the most enjoyment and satisfaction.
Many vehicles were looked at in great length but one stood out from the rest. Arguably the most difficult and lengthy kit to build but one that would bring great satisfaction. An Ultima GTR.
A little introduction into who we are before we get started on the build. Father and son Gerry & Jaime. Have been in business selling glue for many years and always had an interest in Motor Sport / Kit Cars, anything that looks good and goes fast basically. This division of our company supplies high performance adhesives to the above industries. Through this we found ourselves exhibiting at various shows, that is the main reason behind building the Ultima. Been surrounded by all these fantastic kit cars wetted our appetite. We wanted to be part of it, not just supplying adhesives. We hope this build diary makes good interesting reading. Inspires others to build an Ultima and shows how committed we are to the industry.
The Build
This is our workshop (garage) Where we plan to build the car, Spending most evenings, weekends and any other hour we can grab.
Was expecting something a little more
glamorous than this!!
Does the job though.
The first 8 stages ordered were as follows, upgraded items include: Uprated bushes, full roll cage, alloy double skin kit.
Chassis
Alloy Panel Kit
Pedal set - Master cylinders
Wishbones - Front suspension upper and lower ball joints
Rear uprights - Rear toe in adjusters - Front uprights
Front & rear hubs and bearings
Handbrake lever and cables
Clutch pipe & fittings
Accelerator cable kit
Battery cables
This is how we intend to work. 4 x 6 Ton jacks. 2 at either end. Offers a good working height
Our first 2 days were to make sure everything was in place, everything we would need to make this build both enjoyable and practical.
Our chasis is sat on 4 x 6 ton jacks, 2 at front and 2 at back. Its very sturdy and going no where and gives us a good height to work at.
Lap top ready, tools ready, on to first stage - Alloy panelling.....
Our first notched alloy panel - Rear Bulkhead
Selection of wrapped alloy panels
ALLOY PANELS
Having had a play with the panels, we could see a fair bit of nothching was needed to make sure the panels fitted well and flat against the section. The panels had to be notched around joining sections and the welds. For this we used good old fashioned files. The rear bulkhead was straight forward enough. A notch in each corner and one in the centre. First alloy panel complete. Clamped in place, it was time to move onto the side panels.
The side panels were a different story. The alloy panels don't fit, so it is difficult to determined exactly where the joining sections and welds would fall to enable us to notch accordingly, so that gave us two choices. Either go for it and hope for the best (although this would probably mean we would no doubt notch out more than is required somewhere along the panel).
Second option would be to use a template first, determined exactly where we needed to allow for sections/welds and then transfer to alloy panel. This giving a more accurate panel. This was the way forward for us and so cardboard was needed, and plenty of it.
With both side templates now complete we could transfer over to the alloy panels.
With the side alloy panels now notched, it was time to transfer to the car and see how it looked. The notches worked well and the panel fitted snug. The only concern we had was where the panel meets the front of the foot well. The panel just seems to come up against the chassis section and because the alloy panel is cut straight and the chasis is on an angle, the panel does not fit great, overlapping at the top and sitting inside the chasis at the bottom, giving you a gap at the top. Having thought this was wrong and we had done something not quite right, we looked further into it and also made a phone call to the factory who stated this was how it was and that a gap was to be expected and to fill with PU.
Right hand side (drivers). As you can see the top of the panel overlaps the chassis section, with the bottom sitting inside creating a gap. This is normal.
Left hand side (passengers).
cb
