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Engineering Changes
My experience is that it is very easy to rough out parts.
It never fails to surprise me how much effort it takes to get the parts
completely finished. There are so many engineering changes - some are
small and some are not so small. Here is a short list:
Fiberglassed panels to improve panel to panel fit - aesthetics
Filled low spots with filler on all panels - aesthetics
Repaired delaminated fiberglass due to uncured liquid foam - mechanical
Remade the back-end of the car - aethetics
Lowered rear of front fenders - aethestics
Ground down 3 layers of fiberglass because epoxy failed to set up
- mechanical
Front transmission cover redesigned - aethetics
Trunk lid cut out and gutter lip made - new requirement
Wheel wells in fenders modified to fit tires - aesthetics
Sunroof cut out and gutter lip made - new requirement
Roof raised - human factors
Trunk enlarged to accommodate spare tire - new requirement
Trunk lid changed to accommodate rear lights - aesthetics
Cut out holes for headlamps in front fenders - aesthetics
Hood hinge changed from front hinge to rear hinge - mechanical
Removed lower grill support - not required
Gas cap fit - aesthetics
Brake caliper support bracket redesigned - mechanical
Heater core changed to accommodate new repacement core - mechanical
Grill support added - mechanical
Kick panels enlarged - human factors
Transmission cover modified to accommodate throttle pedal - mechanical
Trunk lid modified to accommodate weather gasket
Sun roof modified to accommodate weather gasket
Door modified to raise smokers vent - aesthetics
Door modified door accommodate door panel - new requirement
Fenders modified to accommodate front bumper attachment - new requirement
Reinforced hood to withstand hood springs - mechanical
Converted manual clutch to hydraulic - mechanical
Moved master cyclinder to outside of fire wall - mechanical
Modified roof - aesthetics
Redesigned emergency brake - mechanical
Modified frame to accommodate antisway bar - mechancial
Modified frame to accommodate fuel inlet - mechanical
Modified gas tank support frame to accommodate top tank support
- mechanical
Modified front fenders to accommodate turn signals - mechanical
Added inserts to inside of front fenders for gravel shields - new
requirement
Added inserts to inside of rear fenders for gravel shields - new
requirement
Added inserts to rear to accommodate cable clamps
Added drain for convertible roor gutter - new requirement
Enlarged drain for sun roof gutter - mechanical
Changed curve on door panel - aesthetics
Trunk lowered to add more room - new requirement
Car as of March 2005.
Little did I know how much effort would be required
to get all the panels to have a professional look and fit.
I've probably spent close to 4500 hours at this point. Remember
the devil is in the details.
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