Project EXI

The building of a Marlin 5EXi kit car, using a Seat Leon 1.8T 20v Donor

Wed Apr 11 18:20:46 BST 2012

No Surprise it failed IVA

It came as no surprise that it failed the IVA. But a pleasent one as nothing that it faield on cant be fixed fairly easily. The fail points are

  • Headlights - not aligned
  • Front tyre hitting headlight under full lock
  • Steering column to steering rack fixing loose
  • Driver door - seconday lock failing
  • Brake blance bar - needs adiitional nut / weld
  • Warning label needs fixing to master cylinders warning of adjustment of brake balance bar
  • Steering wheel Boss is not collaspable

These things should all be fixable by the re-test date, which is booked for Thrusday 19th April 2012 @ 3.15pm.

All in all not bad failure at all... considering the complexity of the job

Posted by Steve | Permanent link | File under: iva_and_registration

Thu Mar 29 08:20:46 BST 2012

Delivery to Marlin for the IVA


To hopefully get the car through IVA a bit smoother for me I decided to use the expertise of Marlin, a pre-IVA check, and letting Marlin put it through IVA and register it with the DVLA.

Wednesday 28th March 2012 was set as the delivery date. So on Tuesday 27th March 2012 I hired a trailer from southerntrailers in Four Marks, Alton. And WOW, what a huge trailer compared to our tiny little 1.6 Diesel Golf that we were going to tow it with. It was good solid trailer though and well worth a days rental.

Getting the trailer home was easy enough, it didnt have the kit on it. That evening loaded the kit onto the back (had to reverse it on to get a good balance on the tow hook). Strapped it down with 4 tyre lashes. Weather was beautfiul, warm and sunny, so didnt have to worry about covering the kit to keep the elements out.

Set of from at 7:15am, had made lunch and took some flasks of coffee with us. Down the A303, we were averagin 50mpg !!! I was stunned, this 1.6 diesel golf towing this huge trailer with my kit on it. Putting on cruise control helped alot. Stopped for break at Cartgate picnic area. Having done this trip a few times this about halfway betweem Basingstoke and Exeter. Refreshed and re-fuelled it was time to get ont he road again.

Driving through exeter was a bit of giggle, this is the first time that my kit has been seen by the masses, there were alot of people pointing and looking at the car on the trailer. Quite amusing in many ways

Arrive at Marlin factory at 10:30. Gave Mark a run over on the car, first impressions from him were reassuring.

Left Mark at 12:30 and set of back home, managed to get the trailer back to Alton by 4:30. That saved us and early morning exit to drop the trailer back by 8am.

Just have to wait for the April 11th now

Posted by Steve | Permanent link | File under: iva_and_registration

Mon Mar 19 07:57:19 GMT 2012

IVA Date confirmed

The IVA has been confirmed to be on the 11th April 2012, at Exeter.

I have booked a trailer and will be taking the car down to Marlin for a pre IVA inspection check on the 28th March 2012.

Almost there :)

Posted by Steve | Permanent link | File under: iva_and_registration

Mon Mar 19 07:53:27 GMT 2012

IVA Detailed check

With a freind of mine I spent saturday going through in detail each line of the IVA inspection manual, and checking over the car. 3 hours later we had done all the tests that we could, and had a list of areas that could do with some further work on the car. The main areas were the fixing of cables around the around, some could rub against others or the body work.

So sunday morning was spent correcting a lot of these potential areas.

Posted by Steve | Permanent link | File under: iva_and_registration

Sun Feb 19 14:33:56 GMT 2012

Reflectors and exhaust clamp

One of the IVA requirements are rear reflectors, Ihad initially bought some reflectors but these were stupidly small, looking around on the internet go-outdoors had a set of 2 for £1.35p. At 58mm in diameters these were the exact size needed for the small indent on the rear clam shell of the Marlin 5exi. Fitting was very simple, I held the reflectors in place and drilled a5mm hole through the GRP, and held it in place with a 5mm set screws and nyloc.

My exhaust tailpie kept moving, so to fix it in place I bought a 66mm exhaust clamp. Removed the rear most section of the exhaust, and cut some slots in the metal work, so the clamp would tighten and grip the upper section of the exhaust. I gummed it up with some high temp, red sealent, re-assembled and fitted the U-clamp over the two sections. This now hold the exhaust firmly in place.
Whilst I had the lower section of the exhaust on the ebnch, I also gave it a polish with some autosol. It now gleams, and has removed all the stains from the stainless exhaust

I have re-fitted the door hinge locking pins, so now the doors are fixed into the ball and sockets joints. The passenger door needed some packaging washers to line the ball join up correctly.
I spent the rest of the day with a vacuum cleaner, removing piles of dust from some hard to reach places, to give the whole kit a good clean.
Not sure what else is left to do now, but I'm sure I can find something to do prior to the IVA. Double check and triple check everything wont hurt anyone.
Just looking for the IVA date now. Will keep you all posted

Posted by Steve | Permanent link

Sat Feb 18 18:13:32 GMT 2012

Front stone guard and undertray

The last big push is now on, I removed the front clam shell and went to fit the stone guard for the lower air intake
Bought a while ago from car builder. The stone guard is black anodised aluminium mesh. Cut it to size and folded the edges over the opening about 50mm around the esge would do. Then drilled 10 6mm holes through the aluminium mesh and into the GRP, the mesh is then held in place with stainless penny washers and M6 set screws, with nylocs.

Also refitted the front under tray, now the small water leak from the heater circuit has been fixed. I decided to remove the heater control valve complety, So my windscreen demist is permantly on. The only thing with the front under tray is that water from the windscreen will run down and onto the front undertray. With no way of escape I drilled some small drainage holes, and scored some lines to these holes, to try and give the water a flow channel to drain away. Wether it will work or not remains to be seen :)

Posted by Steve | Permanent link

Fri Feb 17 17:16:32 GMT 2012

IVA paid for

just had the call from VOSA and have paid my &ppound; 450 for an IVA. Next my application goes to the technical department for a review, then the test center will call me and arrange a date for the IVA

Posted by Steve | Permanent link | File under: iva_and_registration

Mon Feb 13 08:16:48 GMT 2012

IVA submission

I've now done all the small little jobs, so I would now call the build is complete.
I had a water leak on the heater control value, so I decided to remove the heating control permantly, and have the heater demist always on, it can still be turned on and off via the fan. This will suffice for the time being until I get throught the IVA.
Also had a small elak on one of the water pipes at the rear, just behind the alternator, a re-tighten of the hose clips seems to off done the job.
Fitted the internal mirror, fitted the chassis number plate, laquered over the stamped in chassis number, fitted the last P-clip to the wiring loom in the passenger footwell, refitted rubber floor matting.
Completed all the IVA paperwork, amatuer build declaration,scanned in 12 of the Major build receipts, and put together some photographs of the build at various stages. Put them in an envelope and sent it all off to VOSA. Im going to go through IVA with the help of Marlin, so need to get the car down to exeter in the next few weeks.

Posted by Steve | Permanent link | File under: iva_and_registration

Tue Jan 24 08:23:48 GMT 2012

Nearly there


For the first time in well over a month I was able to get two days to dedicate to getting some of the last few jobs done on the build.

Firstly I removed the rubber trim I had previously put around the number plate holder. I found a better way of doing it, by cutting down the depth of the rubber trim it can be made to go around a tight radius better without foliding up on itself.

I have fitted the windscreen surround, and self tapped this into place. Im not 100% happy with it, in once place it didnt fit smooth to the screen, and hence wouldnt sit in line with the GRP side panels, I have had to trim it down so it just a windscreen surround that does not meet the GRP. Perhaps one day I can come back and re-visit this. I may have to make my own surround as the Marlin supplied one didnt work for me.
With the surround in place, I glued on some rubber u-trim to its reverse, (passenger compartment side) just to make sure I pass the IVA radius test.

A couple of cable tie bases, stuck to the rear clam shell had come off. Some contact adhesive later and these are back in place.

Stamped the chassis number into the chassis, not sure why it wasn't done before, it should of been done prior to delivery of the chassis. Spotted and fixed now. I also took the oppurtunity to repaint the chassis cross members that are on the floor. This time with black hammerite paint, so it now looks the same as the rubber floor mat texture

One last job is to laquer the chassis number area, fix the chassis plate to the floor.

And fill out the IVA application form. The delting kit car show is Easter weekend, so it might be good to get the car on the road in time for that.!!!

Posted by Steve | Permanent link

Tue Nov 29 07:57:20 GMT 2011

Wiper arm & blade


Now the windscreen was in I needed to address the wiper arm and blade. Measuring from the turret to the middle of the screen was 18", so a wiper arm 18" or 19" would give maximum sweep. From this point the top and bottom of the screen is 14". So a 26" long blade would seem to be ideal.
I was able to find a 19" long wiper blade from a Corsa, and purchased a 26" flat blade from Halfords for £15. Job done!!. It sounds like a large blade but it does clear the most of amount of screen, which I would of thought was the whole idea

Next was to fit the washer jets. A simple job, drilled 2 8mm holes in the dashboard front edge. 70mm from the turret bolt holes. Fitted the two jet heads, and connected up to the washer bottle pump. Filled the washer bottle and aligned the jets. Four jets creates a good spread of water and plentiful so keeping the screen clear shouldnt be a problem

I still had an annoying leak in the water system around the heater matrix control valve. So again took the hosing off, this time I used some PU glue to seal things up. If it leaks now then there is a bigger problem. Refilled the system and went around bleeding the air at key points. In doing so I broke the thermostat wire for the radiator fan control. These cannot be repaired, so I have had to order another one from CBS. In with that order is an IVA ok internal mirror, the adhesive glue for the mirror, some PU glue, adjustable thermostat, and some 13mm nut covers for the windscreen wiper.
The order should arrive today (Tuesday)

Posted by Steve | Permanent link
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