Column with full spacers  I spent some time yesterday fiddling with the steering column. I test fitted the control stalks and the surround when I realized that the column shaft had to be compressed against the large spring in order to fit the steering wheel hub. I made a collar to fit the shaft so that I could use a nut to run down the shaft and compress the spring. But before I actually did this I jumped on my bike, because it was a nice day, and rode down to the hardware store that is five miles away. I purchased some shorter M5x1.0 screws for the stalk attachments and also for the fuel sensor. I also purchased a non-locking nut for the steering shaft so that I would not waste the supplied nyloc nut during this trial assembly. Once back home I slipped the collar I had made onto the steering shaft and ran-down the non-locking nut, which compressed the spring. Then I was able to anchor the column on the two attach bolts except not using the nylon spacers. So then, when I backed off...

Rear brake line On Christmas day I finished installing the brakelines. I wished I could have made the neatest bundle of lines around the master cylinder but I am not displeased with my result. I used a tubing bender to make the 90-degree bends and did the rest by hand. The front lines are a little long and I will have to cut the tubes and re-flare the ends when I am closer to aligning the front suspension parts. There doesn't seem to be a bracket for the attach point between the copper tubing and the flex lines but from the build guide it looks like they are just attached at the side panel. That seems a little flimsy to me! Front brake lines added  The routings of the lines are different for LHD so I simply used the smoothest bends and a path that flowed around the chassis bits. I am not tightening any of the fittings at this point, in case I have to move anything around later.  I then got started with the wire harness routing. The mounting plate behind the scuttle was provide...

 I had a chance to fit up the bonnet to the top of the body and make a measurement between the bottom frame rail and the bonnet side closest to the nose. My engine stands 21" between the bottom of the crank pulley and the top of the cam belt cover. I wanted to know if it would clear the bonnet at that point. The answer is yes! The bonnet slopes upward from the front and the cam belt cover will actually be about 5 inches aft of the front of the bonnet. It's good to know that I won't need a "power bubble" grafted in.  There will still be issues with the manifolds and turbocharger but I would like to fabricate a new upper intake to reposition the throttle body to face aft with the intercooler across the back of the engine. Then I can fabricate a scoop and opening for the intercooler at the aft end of the bonnett and the scuttle. I think this will look good and be the most efficient use of space. I started routing the brake lines also. Being a LHD GT the brake routin...

Assembly work has begun with the installation of the steering and pedal box. The steering column bushing is set in a rubber grommet and was a struggle to install because it is so tight in the cold garage where the rubber was too stiff. After putting a space heater on the floor below the pedals I could keep the rubber flexible while I worked the bushing into it. I got help and inspiration from  Richard's GBS Zero Blogspot   I think I will find a rubber gaitor for the firewall side of the steering column just to give it a more finished look and seal around the gap. Getting the column into place and engaging the lower steering shaft went just about like the Assembly Guide but then I had to slide the spring clip down to keep the bushing in place and clear the brake pedal travel. Lots of fiddling to get the pedal shaft installed because the center bushing was not quite straight but once I opened up the hole a little bit on the inboard side of the pedal box then it could all be as...

After the ordeal of transport was behind us, Bob and his son-in-law Justin came back the next day to help me unpack the crate. Of course, they were curious about how the Zero was going to look. We got the front of the crate off and revealed the beautiful blue and white beginnings to my car. We were all pleased to see that the contents of the crate were in good shape, having been carefully packed at GBS. I had volunteer duty at the Genealogical Center so I could not continue until Sunday, when my friend Jim could come over to help unpack. Jim was a big help but we could have used at least two more people to man handle the Zero chassis onto the cradle, but with only two Jims we made do. With a series hoisting, jacking, and rolling on furniture dollies we positioned the chassis in the garage and could use my lift to raise the chassis and position it on the cradle. Later, when I have the suspension on I won't be able to fit the Zero between the lift rails so I will need a gang of peop...