My Aeon GT3
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Day 78 - Rear corner, exhaust, rear lights

Yesterday, I'd done the offside rear body corner, and today I did the other side.

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This is a lot closer than the other side (I'd learnt from my mistakes!)

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I also welded a bracket to take the other wire rope on the rear section.

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Then, my extra exhaust bits turned up, so I carried on with it. First of all, I needed a tight right angle in order to fit the new tailpipe.

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This took quite a long time - and I was quite lucky with the angle I achieve, because I didn't do any calculation whatsoever. I just cut four 1" v-shaped slots every 1.5", and was surprised when I bent it that it was 90°

This was what I ended up with.

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I then took it off the engine and took pictures of it outside. Later on, I'll get them TIGged.

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I then fitted the battery and stand.

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The strap is covered in loom tape to prevent any accidental short circuits. It's actually very strong, and doesn't move at all.

The other day, I'd had a slight accident with the filler cap when the bolts got snappe off. I made an aluminium plate to hold them down, and all of them are Sikaflexed in place.

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I then cleaned out the interior, and put Sikaflex on the corners of the rear sections where the seats will lie.

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I've got a lot of dust on the camera lens now, so tomorrow I'll get some cleaner. That's why there's a lot of "fog" when there's a strong reflection.

Another thing I've been working on for a bit is the gearbox mount. I'd originally made it solid, but it needed to have a rubber bit to allow some movement. This is an exhaust bobbin.

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The next job was to stick an aluminium sheet to the underside of the rear section above the exhaust - when it was there, I drew a rough outline of the area I wanted to cover.

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And this is the sheet in place (held down with packing tape - masking tape wasn't strong enough).

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I then wanted to put all the rear lights back in - some of the threads had become covered in dirt, so they needed cleaning with a die. I'd forgotten how much I liked it!

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And the final touch was to put the three seats in.

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Unfortunately, the nearside seat interferes with the handbrake, so I'll have to do something about it (either move the handbrake over a bit, or move it up).

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