Side panels. The GRP bodywork doesn't come all the way down to the side panels, there is a gap of several inches. In the demo car there was a curved piece of aluminium which I was going to replicate. Problem is, I'm out of aluminium. This isn't a huge problem, I couldn't have used the existing aluminium anyway. Trying to put a nice curve into 2mm aluminium would have been very hard work!! Once I have the measurements I'll order a 1mm sheet which should bend easier. It's only a decorative panel so it's not an issue.
Side panels 2. The bodywork attaches to the car at the rollover bar mounting points, and comes in at the corners where the occupants shoulders would be. From memory, this distance was shorter than the actual metalwork width, so once the panel has been fitted I'll need to trim that back. As with the side panels, this might result in a section that needs to be filled by aluminium.
Engine height. Hopefully this weekend I'll be getting everything out of the garage so that I can trial fit the engine. This will be so I can fabricate the mounts, and figure out how much space is available in the engine bay for everything that has to go in there. The main issue is how high to mount it. The general opinion is to have it as high as possible in relation to the bonnet. Even so, this tends to leave the sump hanging below the chassis, which is a good thing. But I don't have a bonnet, or at least I don't have an easily accessible one that I can use to measure. I am hoping that the trial fit of the rear bodywork will give me a height to work to. From there I can work out where to put the engine.
Front part of the rear bodywork. The main tub of the car is made from one piece, with a built in 'firewall' at the front that fits on to the chassis. As above it seems to be designed for a narrower car, (or deliberately moulded small to cater for most chassis variations) so the opening isn't big enough to fit over the bodywork. I'll need to open it up in order for it to fit over the car.
Engine mounting and 'the extra bar'. The plans have a section of a crossmember that is removed in order to allow the engine to fit. I've yet to figure out why, it seems like an ideal position to reduce some lateral flexing, and engine bay pictures suggest there is clearance between the bar and the engine. At the moment it's still there on my car, but if it gets in the way of the engine it will need to be removed.
Engine mounts. I have the original engine mounts from the MX5, and it makes sense to reuse them. The mounts themselves are an angled design that contain a rubber bush, so I think they'll be perfect for fitting. The Saturn plans actually disagree though, they say that a bush in shear isn't a good plan. I'm not sure why, MX5's have had them in that design forever, as have many other cars! I've asked the font of all knowledge, IE locostbuilders, lets see what they say. I did find a picture of an engine mount;
And a gearbox mount;
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