Exterior projections / mirrors

 I have surprisingly few 'exterior projections' to deal with, a lot less than an average Locost or Haynes Roadster. With the suspension entirely enclosed that removes a whole load of work. Overall the only things that are considered projections are;

• Lights
• Roll bar
• Centre mirror
• Wing mirrors
• Fuel Cap
• Boot hinges and lock
• Bonnet bolts

The lights were sorted a while back. They all comply as they are, except for the reverse and fog that needed rehousing. That's all done.

Roll bar needed a bit more work, the 3D printed covers do the trick though. 

Given the touch points of the sphere they're probably a bit overkill, but it was just easier to do them as one unit either side. The seat belt mounts are similar, and that's all that can be contacted.

The centre mirror was all over the place, it needed a full back cover to protect it. However that same cover also prevents the sphere from touching the lower fixing so no more needed there.

The wing mirrors were mentioned in my last blog post and also needed a decent amount of work to comply. 

The outer edge of the glass was less than 2.5mm so it needed something. The clamping bracket might have been ok but I didn't want to risk it. 

I'm happy with how they both came out. The ring around the outside is a press fit and will not budge, and the centre bolt bracket tightens up with the bolts. Ironically the 'pointy' bit at the front is compliant, and (just) meets the 2.5mm radius requirement

The fuel cap was bought as an OEM mini cap so nothing to be done there. Similar with the boot hinges, while they are contactable on all surfaces by the sphere there are no sharp edges to deal with.

The boot lock was a potential one, while the outer edge was rounded the underside and the bolting plate 'could' have been an issue. A quick sphere test shows the only part contactable is the outer edge so I'm happy that will pass.

And lastly the bonnet bolts, which I have covered before, literally and figuratively. 

I also did the floor line test today, as expected the rear and sides are of no concern but the bottom lip on the front constitutes the floor line. Having a quick feel along the front edge shows no particularly sharp points but I'll get the gauge on there and see if I need to give anything a sanding. That's all it will be though, I don't think there's enough exposed edge to warrant the push on trim. 

Another job completed today was the correct attachment of the interior trim, using silicon sealant instead of tape. I need to let it go off before removing the excess but I'm 99% sure it'll be secure enough to pass the test. 

I also need to let it go off to finish a job I remembered a while back, trimming the handbrake cable. I left it with a long tail so it's good to trim it to length now. I'll also take a few photos with the panels removed, I suspect Mr IVA will want to see inside the tunnel anyway but I'll take some photos as well.