Self-build frustration

[AG2728]

Hi

First post on Blatchat and nearing the end (hopefully) of my 420R build which I started in July. So hello 

After having researched various, very helpful build blogs both before and during the build, from which I created a mental sh1tlist of the areas that were likely cause me some grief, I considered my self to be fully prepared. I have been building single-handedly and in a single garage, which was bound to throw up some challenges anyway.

I had anticipated that installing engine/gearbox on my own would be be an issue due to bulk/weight, lack of maneuvering space and the tight fit in the chassis. In reality with the alternator and throttle body removed it all slotted in with remarkable ease.

Nightmare big bolt at top of LSD casing? Ground a chamfer on the end, plenty Copaslip. couple of hammer taps. Not a problem. These and all other areas of concern were seemingly behind me. Or so I thought.

My car is an S3 with lowered floors and yesterday with all Sunday to play, I thought I would treat myself to an easy day which would show much visual progress and make me feel good.

Three words - Tillet f***** seats!!!!

Six hours in (just on the passenger side!!!) and still unable to have completed a seemingly simple 4 bolt exercise, I nearly gave in and put my spanners on ebay.

I could choose whether I wanted the seat to pass the harness mounting brackets OR to sit flush to the floor OR to line up with the holes in the floorpan, but it seemed I could not have all three.

At 10pm, for some reason I still cannot explain, the seat dropped into a perfect position. All bolts were threaded in from underneath and everything was good. For a few moments. Until I nipped up the last bolt - and spun the rivnut in the runner - and the bolt has loctite on - and it wont unscrew - and I am tired and I am unhappy.

Tonight I will either grind off the bolt head with furious anger and start again - or maybe I will just go for a pint. What an absolute b!tch of a job. I just had to tell someone. Thanks for listening.

 

 

 

[Jonathan Kay]

Welcome.

We're listening.

Nightmare big bolt at top of LSD casing?

Mine was.

Where are you?

Jonathan

[ChrisC]

I had a seat runner rivnut spin, I found the easiest why to remove the bolt / runner was to drill it out, but had to buy a decent drill bit to get through the bolt head. 

 

[AG2728]

I'm up in the North West.

Yes Chris. That seems like a plan.

[DJ.]

That is a pain to say the least 

I don't suppose it is one of the front bolts? If so you might be able to wedge some long nose pliers in far enough to get someone to grip the rivnut inside the alumnium box section. Otherwise, I think grinding the head off will be least likely to damage anything, at least the washer should protect the floor.

When refitting, I use plenty of copper grease and a spring washer with low torque and have never had one come loose.

Duncan

[clarkey]

Your post brings back my memories from 2002!  I found adjusting diff alignment tricky - I reckon the diff took longer than engine and gearbox.  I then found Tillet seats bloody challenging, especially on the passenger side with an exhaust in the way in a single garage.  I gave up one night and slept under the car, it was much easier the next morning for some reason!

Good luck, it's worth it in the end.

[Wrightpayne]

I fitted tillets once - used threaded rod into the seats then spring washer / nuts under the car

[Roadsport06]

My big cock up was diff in, then diff out, prop in, diff in.

Going for a break seemed to do the job when I struggled with something and then it was usually simple on returning.

[7 wonders of the world]

If your using adjustable runners on the seats have some plain M8 nuts welded inside the channels and use button heads from underneath with penny washers, make life a whole lot easier.

What part of the country are you in ...?

 

[AG2728]

DJ - It is one of the rear rivnuts which spun. Spent tonight stripping it down for repairs tomorrow.

Wrightpayne - Not a bad idea at all.

7 wonders - I've managed to fit the adjustable drivers seat this evening after opening up one of the holes in the floor slightly. Its the fixed passenger seat where my problems lie. I am in up in Lancashire.

[SLR No.77]

If the rivnut's spinning, when you have the seat out use a rivnut gun to "re-set" the rivnut .... however much copper slip you use if you don't it'll be the same problem if it has to come out again.

How far up in Lancashire? The MADS (Merseyside & District Sevens) meeting in Appleton Thorn is the last Wednesday of the month, good to kick some tyres (or Tilletts!).

Stu.

[AG2728]

Stu - When I removed the runner, I could see that the rivnut was more than 'spun' as it was actually detached. When I managed to extract the remnants of the bolt, the rivnut just fell out.

I have fitted a new rivnut at work this morning so I can go for a second attempt tomorrow night. Hopefully won't be another 6 hour marathon.

I am not far away as I live in Wigan area and work in Warrington. Wednesday evenings however are one of the few times I am able to string together a few uninterrupted hours on the car and I really want to press on and get it built. The first meeting I go to, I hope to be driving the thing.

Cheers

Andy

 

 

[SLR No.77]

I like the way you still refer to Wigan as Lancashire   My office is in Leigh (also "Lancashire"!) ... I did live just north of Warrington but in Chester now. 

Stu.

[TomB]

Wigan not far from the Lancashire Area District meeting in Horwich, just on the hill behind Bolton.

[SimonR300]

Andy,

You might find some of my experiences of interest/help, or not.

https://www.lotus7.club/forum/techtalk/tillet-tr1-runner-sv-lowered-floor

I've just had the passenger seat out again for a hillclimb and the loctite I used did require quite a bit of torque to undo the bolts, well more than I was happy with bearing in mind the torque figures described above.  I think I'll refit the seat without loctite in future and just rely on fresh spring washers or shakeproof washers.

[AG2728]

It is a technicality.

I live in Orrell which is in West Lancashire.

But my next door but one neighbour, less than 200 metres away is in Greater Manchester and less than a mile down my road I am in Merseyside. Probably why I'm mixed up.

[AG2728]

Simon - Yes I think you are right. No intentions of using Loctite this time. Spring washers are the future. 

[SLR No.77]

I use hex-head bolts and plain washers ... when you’ve bottomed our a few times you’ll be glad they’re not in too tight. Never had an issue with them working loose.

Stu.