Cab sides, roof and that bl**dy peak all complete and cleaned!  Time for the paintshop.

NB...This will be the last addition to this page. To follow the shale cars' progress through the paint and assembly process please go to the 'PAINT AND ASSEMBLY' page.

The almost completed chassis, just a few 'rough edges' to knock of and final alterations to make now.

Ian fabricates the dash panel prior to fitting inside the cab. Paying particular attention to the recesses for the steering column bracket and gauges.

Dash panel fitted.

Bob welds the nearside cab side into place with the chassis turned on its side to make life easier.

No rest for the wicked (sorry righteous Bob!)...it's time to roll the chassis over and fit the offside panel now.

Underside all cleaned, detailed and ready to go!

Once Derek, Bob and the team are happy that all the angles are covered it is time to "clean up" the bare chassis in readiness for a trip to the paintshop.

Axles and running gear removed, the chassis is inverted for fitment of the sumpguard and further welding to the underside of the car.

On it's wheels!!!

With the team happy with the basic chassis work starts on stripping it off again for final checking and welding up.

It may not look much here but it is components such as this brake cylinder mounting which take a long time to fabricate. This "piece of engineering art" is a prime example of the unseen work that goes into building an F1 stockcar.

12th April 2003

This is the same cylinder bracket shot from inside the cab, also shown is the steering column support .

Getting there now?!...Lower side covers, bonnet, aerofoil mounts are now all but complete. The bonnet scoop is currently "under development" and once everything is sorted it will be time for the chassis to be finish welded. That's Bryan in the background along with Ian (unseen under car) working at such a frenzied pace they are just a blur!!

From the side you get a better impression of how the car will eventually look. Lower, sleeker and lighter is definitely the theme but it is also important that the car retains some individuality. Once this process is complete the car has to be completely stripped out again, finish welded all round (including the underside) and then taken for final detailing and painting which will be the subject of the next update.

A closer look at the roll cage as various panels are tried in place before final decisions are made regarding their shape and profile. The team want both of the new cars to be a credit to the sport and many "discussions" about it's appearance are being had at the moment! 

Look carefully at the detail in the chassis and it is obvious that there is a massive amount of work involved in building an F1. Note attention is now being given to designing the roll cage panelling with Derek's trade mark peak roof panel sitting on top of the screen mesh.

With bumpers, nerf rails, axles and suspension mountings all measured and in place the car is now starting to come together. A lot of time has been spent setting up suspension, engine, radiator, brake and seat brackets. Hopefully lessons learned from previous seasons will pay off with the new car.

25th January 2003

Rear axle geometry is checked throughout the build process. Note the angle at which the 'stay bar' is set can be altered. This allows the bite angle to be altered to suit changing track conditions and helps to maximise the 'contact patch' between the tyre and racing surface.  Although the car is primarily for shale use, as much adjustability is being engineered in.

25th January 2003

Derek sits in the car to help with positioning of the seat and pedal brackets etc.  The phrase " a face only a mother could love" springs to mind.

25th January 2003

Rear axle temporarily in place whilst suspension mountings and brackets are welded into place.

25th January 2003

The position of the major units is carefully measured and marked, the seat placement is checked and things are starting to take shape. 

25th January 2003

Steady progress has been made since our last visit with the under carriage, rear axle, rear swinging arm and engine in place.

18th January 2003

The diff is stripped out of the axle and checked thoroughly before eventual fitment into the new rear axle on the shale car.

18th January 2003

This is the rear axle which, having been shortened on one side, is having the mounting brackets welded into place.

18th January 2003

Looking back through the cab from the firewall.  The bar in the centre of the picture is for eventual connection to the rear axle to avoid/prevent the twisting action of the axle as 500+ bhp is transmitted through the driveline. This piece of kit also helps dictate the angle at which power is transmitted onto the ground.

18th January 2003

A new, lower, sleeker roll cage for the shale car in 2003. Note the amount of steelwork evident in the structure of a six point F1 Stockcar rollcage!

18th January 2003

The new shale chassis, complete with roll cage and dummy engine, being prepared for suspension mounts etc.

18th January 2003

One of the more important team members! The Fairhurst transporter and sustenance unit which is available for sponsorship for the 2003 season.  If you think your company could benefit from advertising on our bus then contact us HERE or call by the transporter at any meeting from Wimbledon to Cowdenbeath!