Build Diary

Details: Written by: Gordon; Category: Build Diary; Published: 12 October 2025; Hits: 5

Back in August 2020 when I restamped the updated VIN to the chassis I felt I might be able to improve on the poor quality factory supplied VIN plate. Now that I have small milling machine with CNC control, I experiment with some aluminium sheet and engraving bits. I use Fusion 360 to import a copy of the Ultima Sports Ltd text along with typing in the new VIN. I am pretty pleased with the results.

Now that the centre tub has been secured it is time to fit out the dash. All gauges, buttons and tell-tale lamps are installed without any dramas.

The battery cables are tidied up the washer and brake reservoirs are fitted.

At this stage it is time to perform a final fit on the fuel system and then fit the engine

Back in April 2020 when the initial engine fit was performed I had to shorten the 'Autobionics' custom cooling S pipe.
Because I had removed the bead off of the end of the pipe, I need to recreate this to prevent the possibility of the silicon hose slipping off when under pressure. I investigate beading tools but for a single job they seem to be too much of a financial outlay. Further googling show some people had success by modifying a pair of vice grips so after watching a couple more videos I sacrifice a set of grips. The result was surprisingly good.

Finally it is time to refit the transaxle and fit the driveshafts.

To lower the car from the dolly I decide that the easiest and probably safest way was incrementally lowering each end. To achieve this I fabricate some longer stand inserts, starting with the longer ones and progressing down the sizes I lower it a couple of inches at a time

Once at ground level I can sit the car on some wheel skates I have recently bought allowing some sideways mobility.

Details: Written by: Gordon; Category: Build Diary; Published: 12 October 2025; Hits: 7

With Christmas out of the way and the usual New Year resolution in place - to make extensive progress on the Ultima.
I need to bite the bullet and securely mount the side pods and centre body section.

To shim out the rear side pod to chassis mounting, I draw up a simple rectangle in Fusion360, I then 3D print this in various thicknesses.
With some experimentation I eventually identify two that position the rear of the side pods where I need them.

After some final checks I commit to riveting the side pods in place.

Once the pods are secured I have no real excuses not to secure the centre tub.

The original builder had made a bit of a pigs ear of securing the tub, unevenly spaced and most in the wrong place, once I had added my holes to correctly secure the centre tub I was left with a bit of a mess along the front edges.
With some patience I filled these holes and a couple of large chips with gel coat. I used plasticine to form little cups so that the gel-coat was proud and then used cling film to cover the gel-coat to allow it to cure fully.
Once cured I sanded down with progressively finer wet and dry paper and then polished with Farecla cutting compound.

From the paper labels attached to many of the fibreglass panels I believe the colour is LR Golden Yellow (PCP3754) which I obtained from
MB Fibreglass Moulding & Casting Supplies. The match is perfect see below.

Details: Written by: Gordon; Category: Build Diary; Published: 12 October 2025; Hits: 7

Sidepods final fit.

Centre tub final fit.

Engine final fit.

Long awaited exhaust system arrives.

Roll hoop brace relocation.

Exhaust Zircotec coated.

Cracked windscreen doh...

Details: Written by: Gordon; Category: Build Diary; Published: 12 October 2025; Hits: 7

I am still anxious about securing the body tub and keep deferring it. Constantly finding other jobs and distractions to defer that task.
That indecision and over thinking things has certainly contributed to the length of this build.

I remove the rear clam shell to apply some heat protective sheeting to the underside. The sheeting I am using is Adhesive Reflective Gold Heat Blanket from Funk Motorsports.

Details: Written by: Gordon; Category: Build Diary; Published: 12 October 2025; Hits: 5

Getting to the point to secure the body tub to the chassis.
Due to the prolonged build time I am nervous that I may have missed something that needs to be fitted before final fit of the body.
I decide to remove the body one final time and check everything.

With the body off, I double check hose connections etc. I also take some photos of coolant hose routing, rear brake line fixings etc.
Because I have not installed an interior light I also note the connector location if / when I decide to install interior lighting.