Wednesday 4 April 2012

IVA Fixes

IVA Fixes

I have been asked if I can detail the fixes that the factory have made for me to get it through the IVA process.  First off let me say that Simon at GBS was brilliant.  He does all the IVA work for GBS, with help from the other guys and has, to date, put through around 70 cars and works closely with the testers at the Nottingham test centre, so what he doesn't know about  the test isn't worth knowing.

I would also add that as long as you build for the IVA and not for yourself, and have a PDF copy of the IVA manual to refer to when ever you are in doubt, you won't go far wrong.  If that doesn't help, and the blogs and forums can't help, ring the factory.  They want you to pass and be on the road as much as you do, it is not in their interest to have part built cars in garages.

So here are the fixes:

1. Fit IVA compliant steering wheel - remove after test - the old Sierra one will do
2. Fit IVA compliant wing mirrors - remove after test.  My mirrors will be fitted to the windscreen.  You must have the correct field of vision behind you (see the manual).
3. Fit centre mirror - remove after test as you really can't see much through it.
4. Mark heads of bolts not fitted with a visible locking device to confirm they have been fitted with Locktite.  Best to use paint or a permanent marker pen, as long as it is clearly marked.  You may get away with TipEx but as this is not really permanent, it may be best to avoid it unless you know the test centre will allow it.
5. Fit headlamp bolt protection - You can see there is a nut cover and some tubing to protect this.  The actual fitting rod could also be cut shorter to help here.  You can also see the mounting bracket trim going all the way round the end of the bracket.  Doesn't look nice, but has to be done.

6.  Apply some extra trim to the rear panel as you can see on the corner.

7. Apply extra protection to the wing stay bracket. nut covers to the flexible brake pipes.

8. A small amount of trim to a square edge on the callipers, because that is radius tested too!  NB:  Not all calipers will needs this.

9.  The red and black fuel pipes were too long and needed shortening so there was more flexibility to secure them and route them correctly.
10.  Some of the pipes at the rear of the car needed to be secured to IVA standards.  For example, do not cable tie the brake pipe to the suspension arms.  You can use a cable tie round the suspension arm, then pass the cable tie through some tubing and then finally attach the brake cable.  It means it is attached but has some movement to it.

Same with the fuel pipes.  They need to be secure but have some movement.

11.  Added some armour to the indicator wires and bonded the wires to the inside of the  nose cone so they don't touch the radiator.

As for the non IVA fixes, Simon found a few other things that should be watched out for.

1. I had wired the starter motor up wrong and had incorrectly wired the earth. Rookie mistake!
2. The steering rack was too low and the suspension bracket was digging in to the off side gaiter.  If you use the standard steering rack clamps that GBS supply, this shouldn't be an issue, but you need to be able to move the steering rack to adjust the setup.
3. The suspension needs re-shimming.  The washers I have used as spacers are not big enough as the need to cover the face of the neoprene bushes to help prevent them wearing out.
4.  Also make sure all bolts are long enough to protrude several threads beyond the locking nuts.
5.  Watch the spacing on the pedals.  The newer pedals have been re-designed to give a bit more space between them.

I will add any more if I remember them.

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