UPDATE – A new Duratec version of the manual has been created. A New Duratec Build Manual
Flicking trough the build manual this evening I found a few observations which might help a novice builder. These observations are relevant if you are building a 270/310 model.
Manual Build Step | Observations |
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Front wishbones | |
Steering rack | |
Front dampers | |
Front uprights | |
Headlights and front indicators | |
Front anti roll bar | |
Front brake hoses | |
Horns | Drilling the hole for the 420 horns is easier before the steering rack is fitted |
Radiator and cooling fan | Leave until after the engine is installed – easy to damage |
Heater | Leave until after the engine is installed – easy to damage |
Air box / Air filter housing | Leave until after the engine is installed – easy to damage |
Remove bellhosuing | |
Fit bellhosuing to gearbox | |
Fit gearbox to engine | |
Install engine and gearbox | |
Fit some of the engine coolant hoses | |
Coolant expansion bottle | |
Fit more coolant hoses | |
Fuel supply hose to engine | |
Throttle cable | |
Clutch hose | |
Battery and engine earth leads | |
Fit more coolant hoses to heater | |
Fill coolant | |
Air box hose | |
Steering column and wheel | |
Exhaust primaries and collector/cat | |
Hand brake and cable | |
Prop shaft | |
Diff | |
Dedion brake hoses and lines | |
Dedion tube into chassis | |
Rear dampers and brake hose to chassis | |
Rear radius arms | |
A frame | |
Rear anti roll bar | |
Drive shafts | |
Rear hubs and callipers | |
Speed sensor | No mention of earth mod, although still supplied in my kit |
Fit front wheel arches | |
IVA trim front wheel arches | Easier before the front arches are fitted |
Rear arches | |
Rear arch protection | Easier before the rear arches are fitted |
Front side repeaters, number plate lamp and rear lights | Front side repeaters are easier to fit before front arches are fitted |
Fuse box cover, knee panels and rivet side panels | |
Carpet tunnel side panels | |
Carpet boot floor, fit fuel filler cover and handbrake cover | |
Tunnel cover | |
Seat belts | |
Seats | |
Roll Bar | This is not possible after rear dampers are fitted; this should be fitted before the rear dampers |
Exhaust and cat heat shield | |
Nose and bonnet | |
Wipers arms and blades | |
Wing IVA spec mirrors | |
Starter Motor wiring |
Things that don’t appear to be covered by the manual at all |
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Washer bottle fitting |
Catch tank fitting |
Engine loom connection to chassis loom |
Engine temp sender (in submarine for gauge) connection |
Reverse light switch connection |
Gearstick installation |
Gear knob install |
Rear brake line bending and connection to rear callipers |
Bleeding the clutch |
Rear Badge / Sticker location |
Aero Screen and mirrors |
Rear view mirror |
Bonnet / nose protection foam |
Complete boot and rear panel carpet fitting |