Kit Car Builders How To Build Your First Kit Car
So you want to build a Rush…

Part 3 - The kit arrives

So, you've stripped your donor car of all the parts you need; cleaned, restored and painted all those you're not exchanging for new; and tidied and prepared your work area ready for your kit to arrive. In fact, you're so organised that you've got some time to spare. Is there anything useful you can do with it? Yes, according to Patrick. You can spend the time reading the build manual and making sure you understand it. "If there's anything you don't understand then call the company. We're here to help."

Then the big day arrives when your kit - or at least, stage one of your kit if you're buying it in stages - arrives. Actually, if you have it delivered you'll be in the minority. Most customers choose to collect it from the factory themselves. Either way, check everything against the inventory and make sure you've got all the parts you need.

Now you can start work, and the first thing you have to do to your brand new chassis is something you hope you will never do again - turn it upside down. This is so that you can rivet on the floor panels using the rivets supplied at about 2.5 to 3 inche intervals along the chassis members.


Rear bulkhead side panels can be tricky

Don't forget the adhesive and make sure you don't leave any dry joints because you don't want any difficult to cure water leaks at a later stage. In fact, one of Patrick's tips is to think about possible water ingress at every stage of the build and make sure all the fitting points and mounting holes where water could get in are well sealed.

Once the floor is on you can turn your chassis back over to fit the foot-well panels and scuttle-top panel. Patrick advises taping a piece of card over the top of the scuttle panel to stop it getting scratched after fitting. "It is such a convenient place to rest parts and tools on while you work."


The differential in place

Next come the rear bulkhead side panels, which are fibreglass on the latest kits. "This can be a little tricky", said Patrick. "There are very slight variations from chassis to chassis depending on the type of suspension. You have to use a little bit of intelligence here and get them positioned right for your particular car."

From this stage it's important to think about the order in which you do things, says Patrick. "The manual is very good and most of the time you can follow it religiously, but everybody has their own way of doing things and there will be times when personal preference takes precedence. The important thing is to fit as much as you can while you've got plenty of space."


It's a good idea to fit the differential at this early stage, Patrick says, but first insert the rear 'A' arm ball joint into its housing in the chassis as it's a little trick to do it later. Then you can fit the de dion tube and build up the rear suspension, which goes together easily if you follow the manual. There is no need for any special tools to install the springs.

Patrick's next step on our build was to fit the petrol tank before putting the rear body around it because this makes access to the fixing bolts much easier. He also ran the petrol pipe from the tank to the pre-pump filter and clipped it along the chassis rail to the front of the car. "It would be a right fiddle to do later," he said. "It's important for the SVA to clip it tightly every nine or ten inches. The inspectors don't want to see it flapping around under the car."

The rear suspension

Actually, part of Patrick's philosophy on this build is to try and get all the pipes and cables inside the car as much as possible. His next step is to fit the brake pipes. "At this stage, you want to be thinking of all the things you can do before you put bodywork in the way. It makes access easier and you minimise the risk to the bodywork." And Patrick's tip for bending copper brake pipes. "When I want a tightish radius I bend them round a large socket in my hand. This gives a good radius without flattening - if you flatten them, they are scrap."

The handbrake cable can also be fitted at this stage, which is a straightforward job…especially on the drum-braked car. Then its on with the rear body panels. "Just follow the manual," says Patrick. "Do it by the book and it's easy."


Next Page

Part 4 - The engine goes in