The tunnel

The tunnel

The tunnel in a Sylva is used for:

* The fuel pipes flow and return.
* The rear brake caliper feed.
* The gear linkage.
* Wiring to the handbrake warning switch.
* The cooling pipes to the radiator.

This tunnel is about to be closed up by fitting the allow and decorative carbon effect panels.

I may need a record of :

* Seat belt fixings
* Pipe clips every 300mm
* No vibration hazards to the critical fluid pipes.

 

References

Contents http://sylvabuild.blogspot.co.uk/2012/01/sylva-j15-is-kit-car-designed-by-jeremy.html

Handbrake

Handbrake

The handbrake should have been one of the easier jobs on this kit, however due to a decision earlier in the build to add GRP seats the route for the handbrake cable is obstructed by the passenger seat runner.

Other problems

* The handbrake leaver as supplied fouls the dashboard.
* There is no warning lamp micro switch
* The handbrake needs to be compatible with the prefitted bracket in the engine bay and Hydra OEM callipers as recommended.

It was decided to purchase a kit for the rear cables as supplied by Motorsport-Tools + a balance bar for load sharing of the handbrake force.

I made a number of items on the lathe/mill.
1) - Device to adapt a handbrake cable from the lever to the balance bar made out of hex brass.
 and a bracket to shift the mechanism below floor level. The original design ran inside the passenger seat.

2) Adaptor connecting up the handbrake cable to the leaver and allowing the cable to be serviced/removed.

3) - A method of turning the cable thru 90deg.

4) A bracket for aligning the front cable to the wheel calliper cables

5) - A load sharing clevis assembly to connect up the handbrake while allowing c able replacement without removing the floor bracket.













6) An adaptor bracket to shift the cable terminations below floor level.



7) Test cables to try out the strength of all this and if it actually works





Now why did I put in those GRP seats?

References

Contents http://sylvabuild.blogspot.co.uk/2012/01/sylva-j15-is-kit-car-designed-by-jeremy.html

Dashboard final fit

Dashboard final fit

The dashboard is one of the parts of the build that needs to be right. I feel if you have a tacky dash then it lets the car down big time it also has the potential to give the IVA man a very bad impression. The big issue with fitting the dash is you are on your own in terms of attachment recommendations. I decided to attach the dash in 5 areas to avoid a rattly car in the future. I will probably use some sealer on the top edge, to help with the latter once the car is well and truly finished.

1) Either side of the dash using the switch/closing panel as a fixing.
2) The steering column using a specially machined bracket out of 8mm alloy extrusion.
 3) Behind the 12v Power point using the knurled fixing to attach the dash.
4) Two brackets mid way along the dash, one next to the rev counter the other to the nearside.

A number of the midway brackets were bonded to the dash using Polyurathane adhesive.

I used a Playskool preformed carbon fibre effect dash overlay.

Midway bracket rev counter



Carbon effect overlay

Offside mountings 2 places

Neerside fixings 2 places

Midway bracket behind 12v outlet