11Budlite Posted September 12, 2007 Share Posted September 12, 2007 Sooooo, I've been trying to get my Birkin ready for my state DMV inspection that was scheduled for 1pm today. I had all the final wiring and fuel hook-ups done and was almost ready to fire it up Saturday evening but figured I'd get a fresh start Sunday morning. So Sunday morning, Nancy runs to the store and gets a new gas can and fills it up with 2.5 gallons of premium while I double check all the AN fuel/oil fittings and the coolant hoses one last time. Put in about 2 gallons of fuel in my new Fuel Safe cell, hook up the freshly charged battery, and turn on the ignition key and everything powers up but the fuel pump??? For some reason the ECU is not powering up the fuel pump relay, so I go ahead and jump the fuel pump relay and the fuel pump starts whirring away! I'll worry about the ECU problem later. But wait a second, the pressure is building real slowly and even adjusting the pressure regulator all the way open it's only going up to 15-20psi??? Now WTF!!! So I start checking voltage to the fuel pump, make sure that the feed and return lines are not hooked up backwards, tap on the gauge, tried cranking to see if it would fire and still nothing. So I'm running short on time because I have a family commitment to attend to, so I figure I'll take a break and think about what could be wrong while I'm visiting with family. So back into the garage Sunday night figuring I'd check the pre-fuel pump filter to see if maybe it's plugged up with some debris from the fuel cell but by then I just didn't feel like messing with gas so I left it for Monday after work. So I get home from work and unhook the line to the filter and NOTHING comes out??? Either my pick-up is not oriented properly or those foam blocks hold a lot of fuel!!! So I get a couple more gallons of gas, put it in, turn on the ignition and the fuel pressure builds to over 65psi!! So I adjust the fuel pressure down to 43-45psi, check for any leaks, turn on the key and crank it over and it fires right up!!! :hurray: I'm ashamed to admit that it's been over 5 years since I've heard this thing run, but boy did it sound nice!!!! So, I figure I have a shot at getting it done for my 9/12 inspection. So I spend Monday and Tuesday nights bolting in the trans tunnel, windshield, seats, seat belts, trunk, roll bar, etc. I swapped the steering wheel with the 14" one from my MGB so that would be legal (can barely get in or out!), wrote the gear pattern on the shift knob to be legal, checked fluids, set the ride-height, camber and toe, aligned the headlights, hooked the ECU wiring to the FP relay to the ground connection (didn't read the manual that said pin 20 is switched earth, not power) and wrapped the exposed header and pipe to make that legal. By now it's 1am Wednesday morning and I'm beat!!! So I take a shower, get about 5 hours of sleep and back at it Wednesday morning knowing I still have to cut a hole in my hood for the K&N filters to poke through. Spend almost 2 hours laying out a template to cut a hole in the hood big enough to clear the filters, but not too big that I can't roll the edges if I'm not happy with the look of the plain edge. Put some tape on the hood, mark out the pattern from the template, and cut it out with my jig saw. File and sand the edges, install it on the car, and it doesn't look too bad. Marked out a couple of small adjustments, a little more filing and sanding and back on the car and it looks nice!!! So now it's 11:45, Nancy has just gotten home, but we still have to hook up the trailer and get the Birkin up on the trailer and tied down (something we hadn't done yet). Thankfully we have no problem with the trailer, we grab the paperwork and were on the road by 12:15 with about a 45 minute drive in good conditions ahead of us. The trailer pulls beautifully even with the Minivan, and were doing 65-75 hoping we'll get there on time. We get there with about 2 minutes to spare and before too long I get two of CT's finest looking over my car. They check the lights, wipers, brakes, Link to comment Share on other sites More sharing options...
yellowss7 Posted September 12, 2007 Share Posted September 12, 2007 Mine fell off :blueangel: I guess the tape that held them on wasn't that strong. Link to comment Share on other sites More sharing options...
slngsht Posted September 12, 2007 Share Posted September 12, 2007 I think Maryland requires bumpers. This guy I knew bought a Caterham and had ALL kinds of problems with the delivery. Finally got the car - tranny went out on the way home. 4 months later, got the car back. Took it to DMV, and they said "you need bumpers" :lol: He got so fed up with the whole thing, he sold it. Fortunately, my car is a historic, so nobody even looked at it :thumbs: Just bolt on a temporary metal bar as bumper, and make sure it's the right height. Link to comment Share on other sites More sharing options...
SkinnyG Posted September 13, 2007 Share Posted September 13, 2007 Mine fell off too. Funny that. They're hanging on a wall in the shed. Along with my rear mudflaps, sunvisor and two-speed heater/defroster. G Link to comment Share on other sites More sharing options...
ottocycle Posted September 13, 2007 Share Posted September 13, 2007 Doug, You might find a cheap set of nerf bars from one of the many Hot Rod suppliers put there that will get you through inspection. You can remove them when you get the paperwork sorted. Fighting the DMV may be noble but it will cost you driving time. Just a suggestion, Good luck, Dermot. Link to comment Share on other sites More sharing options...
Boxologist Posted September 13, 2007 Share Posted September 13, 2007 http://www.dmv.org/ct-connecticut/custom-built-cars.php i searched thru the Ct auto code and olny found 2 mentions of "bumper". one in relation to the exhaust and the other with regards to chop shops. so yes, u will definitely need a live body for advice. once u have that person, get their name and when theya re working. ur gona want to send them something nice after the birkin is on the road. Link to comment Share on other sites More sharing options...
locostv8 Posted September 13, 2007 Share Posted September 13, 2007 You might inform them that the nosecone is a deformable bumper same as most new cars. Link to comment Share on other sites More sharing options...
Al N. Posted September 13, 2007 Share Posted September 13, 2007 Bruce- I think Jim Gunther, Stalker owner, lives in CT. I will send you his contact info and perhaps he can tell you the best way to rig up some bumpers. Also, for anyone who is going to get inspected in NJ any time soon, I have the "exhaust cover" you'll need to shield the 4 into 1. -Al Link to comment Share on other sites More sharing options...
ottocycle Posted September 13, 2007 Share Posted September 13, 2007 Grist for the mill. Along the lines of the group purchase of scales, there might be benefit in the club putting together a DMV kit that members could rent for a modest amount, plus shipping, to get their cars through inspections. Bolt it on and bolt it off after the job is done. I have not thought deeply about it and I am sure each state has its own idiosyncrasies but a list of common parts might get one 75 to 80% there. Just a thought, Cheers, Dermot PS. Doug, I sent you an e mail about the engine and parts you were going to check out for me. Thanks again. Link to comment Share on other sites More sharing options...
xflow7 Posted September 13, 2007 Share Posted September 13, 2007 Grist for the mill. Along the lines of the group purchase of scales, there might be benefit in the club putting together a DMV kit that members could rent for a modest amount, plus shipping, to get their cars through inspections. Bolt it on and bolt it off after the job is done. I have not thought deeply about it and I am sure each state has its own idiosyncrasies but a list of common parts might get one 75 to 80% there. Just a thought, Cheers, Dermot PS. Doug, I sent you an e mail about the engine and parts you were going to check out for me. Thanks again. Wow, that's creepy. I am in the midst of trying to gather DOT lights for my car in the event that they actually decide to check all the markings and was thinking yesterday it would be handy to have a kit, or at least a list, that would comprise at least the effectively federally mandated stuff (i.e. DOT lenses, etc). Things like the windshield would be tricky as that becomes somewhat marque-specific and it may not be so trivial to get a correctly shaped piece of laminated glass with appropriate AS markings etc, even though it's flat glass. My focus on lights so far has yielded the following. My goal has been to find things that I can undo and revert to the standard fitment items without leaving a bunch of extra holes, etc. - Headlights: must be marked SAE H or HR. I bought these Hella Vision Plus Halogen lights. These fit pretty well in the standard 7" Caterham bowls, though the spigot diameter is a shade smaller so they're a smidge looser. Only other issue is that the rim is considerably thinner so requires some some shimming under the hold-downs inside the bezel. But mine are mounted and seem secure. And they plug directly in, so easy job. They have the alignment nipples on the front which are kind of ugly, but don't really bother me. - Tail-lights. Tail-lights (incorporating Stop/Turn/Tail) are usually marked something like AISTP (A=Reflector, I=Turn, S=Stop, T=Tail, P=Parking) is tail All I've managed to find on the tail-light front are trailer lights. I'm going with the ST-16RS from here for now because it is what I could find locally. They're huge and ugly as sin, but they'll work for now. Mounting on the existing holes requires drilling the back of the light and, at they're not contoured on the back, so it is necessary to rig up some standoffs at the top of the light to accomodate the wheel arch curvature and get them closer to horizontal. The other complication is that, as trailer lights, they are intended to use a common Stop/Turn filament, whereas Caterhams have separate filiaments. So to get truly correct functionality is going to mean sticking in a converter like you sometimes have to install in your trunk for towing. Those are relatively small and passive, though, so not such a big deal. - Turn signals are the trickiest. They must have an SAE I marking and very few lights you find around and about have that. I finally found some at NAPA, P/N 1506A that are marked for use as turn signals (I) and also parking lights (P). They are about the size of the marker lights used on recent Caterham clamshells. They are also a little fugly and are slightly complicated by the fact that they are intended to be chassis grounded. So they will require rigging up a ground terminal under a mtg screw or something. - Side Markers: I'll probably use the same NAPA lights, although, depending on what function you call these (side turn signals vs. clearance vs. parking, they need different codes, so I may get something else). The Tail, Front Turn, and Marker lights will all need to be connected somehow. I have some extra connectors on the way from Caterham USA, but apparently they were a Rover Link to comment Share on other sites More sharing options...
11Budlite Posted September 13, 2007 Author Share Posted September 13, 2007 Thanks for all the info and advice guys!! So I contacted the DMV today about the bumpers, but I'm still waiting to hear what their final say is. In the mean time, I checked out different places on the frame that I could hook up to without welding or permanent mods and I think I can do it if necessary. Maybe I can mount my new DOT approved lights to the bumpers so my Birkin can look like a big-rig!! Bruce PS: Dermot, I left you a message on your voice-mail. And who is this Doug character? If he's handy with a wrench or engine tuning, I can use his help!!! Link to comment Share on other sites More sharing options...
slngsht Posted September 13, 2007 Share Posted September 13, 2007 If you decide to make a bumper, make sure it looks something like this: http://www.guzer.com/pictures/finger_cloud.jpg Link to comment Share on other sites More sharing options...
xflow7 Posted September 13, 2007 Share Posted September 13, 2007 :lol: Link to comment Share on other sites More sharing options...
Boxologist Posted September 14, 2007 Share Posted September 14, 2007 dave, there is a caterham dealer upstate, get in touch with him to see what u need. maybe he has some pull. Link to comment Share on other sites More sharing options...
xflow7 Posted September 14, 2007 Share Posted September 14, 2007 dave, there is a caterham dealer upstate, get in touch with him to see what u need. maybe he has some pull. Actually. I spoke with him yesterday. It doesn't sound like it's going to be too big a deal. He said that they often do not actually check the markings. But my viewpoint is if I make the effort to address the issues I can, then if they do decide to inspect I have a better chance of reasoning with them if there's something I cannot feasibly do. Link to comment Share on other sites More sharing options...
11Budlite Posted October 7, 2007 Author Share Posted October 7, 2007 Just a quick update on my Ct inspection process. Spent the last couple of weeks getting my Birkin ready to go through inspection again. I ended up having to build some bumpers and change out all the lights...there was just no way around it. So, I got some 1.5" x 3" rectangular steel tube, 1" round tube, some threaded rod, and some flat stock and was able to fabricate bumpers that bolted to existing mounts on the Birkin frame. No permanent changes or damage of any kind. I bought some Jeep/truck lights, and some Harley turn signal lenses which I was able to mount to the stock Birkin front housings (also used an extra set I had in the rear) by ovaling the mounting holes a little and spacing them out with 911 oil filter o-rings. I also had to use a narrower spare wheel off my kids old Sentra to fit in the spare tire carrier with the bumper in the way. Here's a couple pics of the car on the trailer before strapping it down and heading to the DMV: http://www.usa7s.com/aspnetforum/upload/1904624378_IMG_1180.JPG http://www.usa7s.com/aspnetforum/upload/2137872953_IMG_1176.JPG So we get to the DMV, they check it over and it passes with flying colors!! But, they tell us that the registration dept is closed due to the holiday weekend and we'll have to bring it back next week to get the VIN assigned and attached, and get our plates. So I mention the Michigan title and VIN again, they look it over AGAIN, and decide that the MI VIN is acceptable and all we have to do is bring the paperwork to our local DMV to get our plates!! :hurray: So I'll stop down this week to get the plates and we'll be legal. I still have some tuning to do before I drive it too much, but hopefully with my daughters new laptop (her other was stolen when our house was just broken into - long, ugly story...), we'll get it close and I can start driving this thing!!!!! So, anybody contemplating registering a LSIS in CT let me know, and I'll give you a hand. And anybody with a Birkin (or other brand if it can be modified to fit) that needs some temporary bumpers and DOT/SAE lighting to pass inspection, let me know and you're free to borrow mine. Bruce Link to comment Share on other sites More sharing options...
slngsht Posted October 7, 2007 Share Posted October 7, 2007 Awesome! Except the robbery part :nonod: Bumper looks nice. Looks like it's missing some offroad rally lights Link to comment Share on other sites More sharing options...
Mandurath Posted October 7, 2007 Share Posted October 7, 2007 Odd request, but more pics of the bumpers pls. May be useful for me too. Link to comment Share on other sites More sharing options...
11Budlite Posted October 7, 2007 Author Share Posted October 7, 2007 "Looks like it's missing some offroad rally lights" - I think I could fit about 4 pairs across the top of the bumper, but then I'd have to upgrade the alternator AND jack up the suspension!! Here's some more pics of the bumpers, not very good, but all I have for now: The first one shows the 1" steel tube over the threaded rod I used to replace the upper a-arm bolt. http://www.usa7s.com/aspnetforum/upload/1052958649_IMG_1181.JPG The second one shows the profile of the two lower front brackets that I bent out of 1.5" x 3/16" steel stock. They're bolted behind the bumper and to the frame in four locations - two lower nose cone bosses and two bosses that the front of the sump guard bolts to. http://www.usa7s.com/aspnetforum/upload/1330687704_1509323613_IMG_1175.jpg This is a picture of the rear bumper. It's mounted in three places - two brackets to the lower spare tire mounts and one bracket to the upper-center spare tire mount. I just put some electrical tape over the spare mount framing, rested the bumper bar on it, and marked out the brackets to be cut, bent, and drilled. http://www.usa7s.com/aspnetforum/upload/705235669_IMG_1187.JPG And here's some detail pics of the brackets. On the rear brackets, I was able to use some old rusty MGB bumper brackets I had laying around. The center mount: http://www.usa7s.com/aspnetforum/upload/1253228597_IMG_1195.JPG And the right side lower mount: http://www.usa7s.com/aspnetforum/upload/2052564222_IMG_1197.JPG Hope this helps, and if anyone needs to borrow them or the lighting, let me know. Regards, Bruce Link to comment Share on other sites More sharing options...
Boxologist Posted October 7, 2007 Share Posted October 7, 2007 awesome. congrats. blats. u needs blats! Link to comment Share on other sites More sharing options...
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