g'day and welcome to another episode of built by
dan in today's episode i'm going to be installing the front chassis extension panels and the
radiator and thermo fans in my gt40 kitkat so i'm not sure what happened but i seem to have
lost some footage somewhere along the lines so unfortunately i don't have any clips showing the
installation of the thermofans onto the shrouds however it was as simple as just laying the
thermofans on top marking the location of those holes drilling the eight holes and
bolting it on unfortunately the bolts that were supplied with the kit are too short once
you actually insert them through the thermofan mount and through the shred the hole in the shroud
there wasn't enough thread left to install the nut or the washer basically even if i remove
the washer the thread wouldn't actually pass through to the nylon washer
that's inside the nut so i need to get that resolved but for now it's all held
in place so we can continue with the install and i've just added it to my list of things
to be resolved as part of the final assembly all right so i'm going to start this front chassis extension section by doing the
sides first so a bolt on the sides and then i'll look to bolt on the bottom plate i've been
i mean an ironing for a little while as to which way to do it whether to try and bolt up the
bottom piece first and just put a block of timber underneath the front to support it or whether
i start with the sides but i do believe that starting with the sides is probably
going to make life a little bit easier so that's what i'm going to do i'm just
going to get a couple of bolts in for now and then i can finish it all off once it's all sort of loosely installed okay it's as simple as that bolting this side
piece onto the main chassis it is just four bolts i've tightened two of them up i'll leave
the other two loose for now just until i can make sure that everything sort of sits
as it should now jump to the other side okay so that's the two sides loosely
installed i will now make a start on the base okay so that's just one done up finger tight
this bottom panel does actually sit underneath but i'm just using the sides the little
return on the sides to support it for now um and i can always just either flex
them out a little bit or undo the bolts so i've got all three bolts on one
side one bolt on the other side i'm just gonna see if i can now get the side mounted to the base there
are some elongated holes here so there's obviously a bit of adjustment there
what i might actually do is not tighten these bottom ones up until i mount the radiator in
between because i think that will dictate what the spacing should be between those two sides and
then i can tighten up the base ones accordingly now i approach with these bolts
similar to a couple of other areas appreciating that bolts
should go from top to bottom but given that we're dealing with the front of
the vehicle here trying to maximize my ground clearance and not have the additional nut and
thread from the bolt sticking out underneath which could cause some ground clearance issues
later on this way i just have the bolt head underneath or the screw head underneath and
that's it i'll repeat the same for the other side all right that's everything just
done up finger tight i do still have a couple of bolts to put in from the bottom
here almost forgot about the underneath there and then i think what i'll do is i'll tighten up the bottom panel where i'm currently
putting these screws in now and then we'll look to assemble and install the radiator before i tighten off the sides i feel like a bit of a contortionist at the moment
but it's really awkward to get into where this bolt is right in the corner okay that's all the
bolts in finger tight i'll get to tightening them up and then we'll come back and look at installing
the radiator and thermo fans unfortunately the audio hasn't come through for this clip so just
explain what i was running through here i was just covering off the assembly of the radiator
and thermo fan unit so the fans were bolted to the shroud first and then the shroud is screwed
to the outside frame of the radiator with the supplied spaces in between this holds the nuts
from the bolts that pass through the fan frame and the shroud from hitting the fins of the
radiator for final assembly there is also an adhesive foam strip that will be installed in
the gap created by the spacers to try and ensure as much airflow as possible through the radiator
okay now before i get too carried away with the installation of the radiator i just thought
i'd quickly show you what i have done is just installed this little spacer that goes inside
the grommet just so it doesn't compress too much and i've just put a bolt in
uh the top corner on each side and the reason for that is because
i've just been playing around with how the actual supplied bolt assembly is supposed
to work basically this is what's supplied there's the bolt the nut there's a zinc washer
and then there's two stainless washers so the only thing that i could work out is that
zinc washer on the outside for the bolt head and then the stainless washer either side of the
rubber grommet to hold that little spacer inside that rubber grommet without it pulling through
the um the actual bolt hole in the chassis panel so i don't know if that's correct or not but
it's the only thing that i could come up with that seemed logical based on what was supplied so
i'm going to run with that for now again this is all just a test fit it will likely get pulled out
before the car is finished and then we'll go back together as part of the final assembly so now i'll
have a crack at installing the rest of these bolts and washers i might even just try and get the
bolts in to start with and then i can focus on putting the nuts on later all right that's one side just with the
bolts thread through the holes and the um the spacers in the grommets i might just
go and fix off just finger tight the nuts on each of them just so they don't pop out
while i'm playing around with the other side i think leaving these loose will just
give me a little bit more flexibility to move that around just so i
can get all the washers in and get it all positioned correctly so now jump
to the other side i'll try and reposition the camera so you can see it better what i'm
actually doing and we'll get this all fitted off okay so i now have all the bolts done up finger
tight you can see there i've still got the cardboard sitting in behind those thermo fans
that's because i do still need to take them off and address these bolts uh which weren't
long enough to even pass through the nylon part of the nylon nut nylock nut
a bit of a tongue twister there but i can still at least get it all bolted and
make sure that it all fits now i do actually need to install the air conditioning evaporator in
front of that radiator but there is no guidance in the build manual as to how that is supposed to
be done i haven't been able to get in contact with any other builders that have completed that step
and the manufacturer has not been able to supply any additional information to date so for now
i'm just going to stick with the radiator install as much as i would have liked to do the air
conditioning at the same time and just be done with this section unfortunately i'm not able to
do that so it'll have to come out at some stage when i do that i'll remove the the cardboard
that's on there just to protect the fins of the radiator i'll hopefully have a solution
to address the bolts that are holding those thermo fans on that are too short and
have some further guidance as to how the air conditioning evaporator is to be installed in
front of that radiator i'm going to now tighten off those bolts as i mentioned everything is
still pretty loose i'm going to tighten the bolts to the radiator first and then i'll go and
tighten off these bolts that i've left loose on the side panels and also on the bottom here
where the side panels attach to the base panel okay that's everything tightened off now okay so here's a quick look at everything fitted
off really not much difference to the way you saw it previously it's just a bit more solid so
now show you what i mean underneath in terms of keeping everything or you know trying to maximize
clearance by having the bolt heads underneath i know the manufacturer installed the hinge with
the uh the nut and bolt sticking through however they don't seem to protrude protrude as far as
what these bolts would for the chassis panels so now before i started this i did
actually fit the silicon hoses to the the hard coolant tubes that run through the
center tunnel and here i have the flexible tubes that will be fit off between the silicon
hose there on that center tube and each side of the radiator so this i'm going
to have a look at doing now i probably have to cut them down a little bit but all
in all just try and fit them into the silicon adapters or silicon joiners and and get a
stainless cable tie on there to hold it in place what i'm looking to do now is
to form up these flexible hoses to try and make them work to connect from our
rigid tube that runs through the center tunnel to the radiator so it looks like it's probably
going to be a bit of adjustment required just to cut it down or just change the shape
of it slightly even just to use the full length i don't see why there is a need to use the
full length but i'll probably just try and form this up as best i can and see how i go
i have sort of started from the center piece bent it around just in a snake shape and then bent
it up to come up to the connection on the radiator it is quite difficult to try and get that to
sit right to know what length it needs to be i might even just do it in a number of cuts just
so i don't take off too much in the first instance but i might just keep playing
around and see if i can actually use up more of the length rather
than having to resort to cutting that does get pretty close to using it up i don't think i'd really want to try and make that consume any more than it already has of the hose i
think i might just go and cut that off right there all right so that's cut down now so once that's in i can sort of
manipulate that a little bit still but all in all that's um it's come out quite well i think i might try and connect this central end oops i've got that fell off uh so just want to make sure that i push
that in as far as i possibly can there are a couple of clips
that will go on to hold the hose in place so it doesn't vibrate
and move around too much but in terms of the fitment so far i'm
pretty happy with how it's sitting get that silicon adapter on halfway and tighten
that off before i try and insert the hose so better get that held down
once i get my clamps in place so i'm not too concerned about that that's one
side done now i'll just move to the other side i'm gonna make a start on the other side now i
haven't actually attempted to preform this tube yet so we'll see how we go it is going to follow
a similar sort of pattern so it will come out around along the base and then
up and connect to that tube this time around i might start at the radiator end all i'm doing here is just giving myself
a bit of a guide as to where halfway is for the silicon joiner so i can make sure
i've got an even amount of the radiator and then the flexible hose sitting in there
i'm a bit pedantic about how things look so i'm just trying to work
out what's going to look best for these clamps all right i'm pretty happy with
that i'll have to go and find the the brackets for these hoses i think there's one
here and then one for each end but i might even just look at where it's going to work best i think maybe that corner
will work best but maybe that side be nice to have it all symmetrical now that's just
me being pedantic but we'll see how it works out and that just about sums up today's episode
assembling the radiator and thermo fans and installing them along with
the chassis extension panels so take a step back here you can see that that
front extension panel and radiator assembly really does add to the front length of the front
end of the car it kind of looks a bit awkward to be honest standing here the front almost looks too
long for the vehicle but that will all i suppose resolve itself as i move into the next episode
where i start to install the front suspension so that's all for today's episode thanks
for tuning in if you like these episodes and the level of detail that i'm going into
with the assembly of this gt40 kit car please hit the like button and subscribe to the
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