Anyone have the extended footwell bodyshell?

[Nobby]

I have the 2" extended footwell bodyshell and am having real problems making it line up against the fottplate flange also the pedalbox and servo fitment.

I can't get a nut on the servo studs as the pedal box is not flush against the end of the footbox. Either I grind away the square edges of the pedal box or extend the studs? Also I can't get the brake pipe adapter into the servo as it hits the wheelarch there just aint enough room?

Does anyone else have this problem or am I just lucky?

Nick

[Nobby]

to illustrate the servo problem I have attached a picture. The white box is 2.2inches wide. There's no way I can insert the pipe fittings etc into the servo. The wheelarch gets in the way?

It also shows the gap between the footwell and the flange.

Help!

[mikey]

Dont know whethr Dave has come accross this before. Dont fret though as I think you have two options.

1 Is there enough gap between tyre and wheelarch to cut a hole in the arch to accept master cylinder.

Alternatively try thinking about a remote set up like on the e-type Jag and early Daxes

I would ring Pete up at Dax and chat it through
Mike

[JonnyT]

I am getting the extended footwell - so it is heartening to hear that it all works perfectly!!!

However, I think the answer is that you have to cut a small hole in the wheel arch to accept the servo. Like the last post said - ring up Dax and they will tell you all about it - I have been told but I would be reluctant to tell you to cut a hole from my own recollections!!

I think it does work out fine though. Save of course in the event that you go for an engine that they have never used before fitted to a gearbox that they have never used before either, with the extended footwell just to make the exhaust bending a little more fun - now who would do a really stupid thing like that.........

[NC427]

I have an extended footwell on my dax and issue was solved via cutting a small hole in the wheel arch, install the master cylinder and then cover the hole properly.

Have to add that although I was not too pleased about the necessary modification (which could / should have been done by DAX prior to supplying the shell as I guess they know about the problem?!?) it was worth the effort as now sitting comfort / space in comparison to my previous DAX is a mayor improvement.

Carsten
NC 427

[Nobby]

Thanks to all for the input. chaps. I've managed to get the servo installed at last by grinding off the edges of the pedal box. This allows it to sit flush up against the footbox end wall and the servo studs are just long enough to get a nut on inside the footwell.

I ran Peter at Dax and he told me about the 'Hole in the Wheelarch' ploy, to clear the master cylinder. He suggested using the top of an aerosol can Wurthed into the arch to cover the end of the cylinder. Wonderful. How much clearance is there between the wheel and the arch? I have 17" Halibrands.

I am looking forward to installing the power steering I've ordered. NOT. I wonder how many botches I'll have to make to get that fitted. And of course the build manual (ha,ha) will include detailed instructions on the installation.

I've decided to take up Cat Herding as a hobby instead - it's a lot easier than trying build a Dax.

Disillusioned of Camberley

[craggle]

Hi Nobby

Please don't loose faith in the Dax kit. I have just finished building mine and although the build manual is sometimes vague, just persevere and it will work out in the end.
This forum is more usefull than any build manual could ever be however well written it is.
If you have any suggestions for the build manual tell Dax and they may include it in future revisions.

I design diesel/electric hybrid vehicles for a living and it is surprisingly difficult to write the maintainance manuals on some thing you have designed yourself. It may make perfect sense to me when writing, but give it to a complete stranger and they are lost.

I took my car out on its first proper drive to Brighton yesterday to get the DVLA inspection sorted before registation and all the long hours, cut and bruises during the build, all seemed to fade away into insignaficance.

Stick with it and it will be worth it in the end.

Craig.

[Nobby]

Graig I agree - without this forum I would have been stuffed!!

I just think that the 'Build Manual' should include more detail and even photo's?

And where you have to butcher the wheelarch to fit a basic item such as the Master cylinder, I shouldn't have to scratch around trying to find out how it's done - it should be in there!! Likewise where the pedal box won't fit up against the footwell?

The day when I will get to drive the car seems a long way off. Still - thanks for the moral support. I appreciate it.

Anyway, I seem to be moving forward - albeit slowly!!

Problems still to solve.
Propshaft still 20mm too short.
Wheelarch/Master cylinder fit.
Drivers footwell doesn't butt against footplate flange.

I'm going to meet with Peter Walker on Monday to try and resolve them all.

What else did you encounter during your build that I should look out for???

Cheers

Nick

[craggle]

Hi Nick

Photos would be a good idea in a build manual. A picture says alot more than any amount of writing can.

Strange that when I fitted my brake servo and master cylinder I noticed how close it is to the wheel arch and thought that if I had the extended footwell they wouldnt fit. When you buy the extended footwell they really should include a different wheel arch moulding to accomadate.

I know you probably don't want to hear this but my car seemed to fall together. I can't remember any areas that needed major re-work. Maybe I was lucky.

What gearbox are you using? The prop should have a slider join or on my car the rear output from the box is the slider. I assume the prop was supplied by Dax and not a custom made one to your measurements. The only mistake I made with the prop was to order the standard Tremec one when I had the newer TKO500 box which have different size splines on the output.

Thinking about it one problem I did have was with the centre transmission covers. The front part fitted fine but the rear needed major cutting and re-shapping with fibreglass and resin before it fitted together. There was a thread about this on here recently.

Craig.

[Nobby]

Craig, The prop I have was supplied by Dax, I have the TKO500. I even sent them the splined yoke supplied with the gearbox. They have given me a replacement prop but it's still too short.

The transmission tunnel covers fit perfectly on my bodyshell with no modifications required!! Although I have the Non De Dion chassis. I think I heard somewhere that the problem only occurs on the new chassis?

Just out of interest did you have to bend the clutch pedal to fit the steering column?

Nick