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Site last updated:
June 2011
Build Diary

The Build

This page will feature some highlights from the build process for those just wanting a quick browse.

If you want more pictures and much more detailed information then please use the sub-links under the "Build Diary" link in the navigation menu to the left.

Summer 2004 (no pictures)

I acquired this car at the 2004 National Kit Car Show, held at Newark. It was actually MOT'd and running but was in a very sorry state. I arranged a trailer and towing vehicle and actually transported it a week or so later to my parents house in Co. Durham. I have nowhere to keep it where I live in South Wales, unfortunately, so I travel up North infrequently to visit the family and do some work on the car.

I started stripping it that same Summer and never thought to take any 'before' photographs. The photographic record commences from Summer 2005, when I took a two week break with the specific intention of getting some serious work done on the 'Rat.

In the year between me aquiring the 'Rat and working on it during my 2005 break I spent a lot of time trawling eBay for spares and looking for a suitable donor. From eBay I managed to get all these parts brand new:

• Hand brake cable
• Rear shock absorbers
• Pair of front brake disks
• Pair of front brake calipers

I also purchased the following items second hand from eBay:

• Set of four Cinquecento Sporting alloy wheels
• Porter workshop manual for Fiat Panda

I was also lucky enough to find a mechanically sound donor vehicle which a chap was advertising for sale where I used to work. It was doing duty as a farm runaround so the mileage wasn't astronomical but the body and interior had suffered as a result. At the time ropey Panda 4x4s were fetching in excess of £400 on eBay so I was more than pleased to hand over £200 for it. It was a 1991 model and also came with a Haynes manual.
Summer 2005

Acquired a donor Panda 4x4 and stripped both that and the Road Rat concurrently. Road Rat chassis cleaned and undersealed. Front suspension and steering fitted. Rear axle and suspension fitted.

The donor Panda 4x4 undergoing 'testing'. It was fun.

Road Rat chassis stripped, cleaned and undersealed with Hammerite Underbody Seal.

Panda 4x4 rear axle cleaned and painted just before fitting to Road Rat chassis.

Rear axle fitted to Road Rat chassis.

All suspension and steering components fitted.

Just trying the Cinquecento wheels to see how they looked before putting the car away.
Easter 2006

Replaced the clutch in the Panda 4x4 donor FIRE engine before fitting the engine into the Road Rat chassis. I also had to design a new engine mount for the drivers side as the FIRE engine mount wouldn't fit. Also fitted the drive shafts, gear selector mechanism and 4x4 selector mechanism. The handbrake lever and petrol tank were also fitted.

Lowering the car onto the engine. Easier than lifting the engine in from the top.
May Bank Holiday 2006

Fitted newly fabricated engine mounts and inspected prop shaft.

New engine mount for drivers side.
Summer 2006

Lots of work done on the engine bay and braking system this time. Bonnet struts fitted to open and hold the bonnet. Engine started for the first time since being removed from the donor Panda. Maiden voyage! The car was driven very carefully for a hundred yards or so but resulted in a broken driveshaft.

Hatchback struts fitted to bonnet to open and hold bonnet.

Engine bay work included fitting most of the ancillaries, plumbing and wiring.

Very careful first drive...

...resulted in this! A broken driveshaft.

Putting the Road Rat away until next time...
December 2006

Repaired and refitted the broken driveshaft. Played with the engine and gearbox mounts to make sure both driveshafts engaged properly. Fitted a new brake master cylinder. Drove the car properly this time without incident. Obtained, modified and fitted a sump guard. Finally mounted the exhaust system.

Sump guard fitted before final modification and painting.

Rear exhaust mount overkill!

Quick Time movie - Rat being driven 1
  

Quick Time movie - Rat being driven 2
Summer 2007

Fabricated front frame and rear bull bar. Fabricated mounting points for the three point harnesses. Pained bonnet and applied FIAT racing stripe.

Front frame in process of being trial fitted.

Rear bull bar being finished with integral lights.

Bonnet painted silver and FIAT racing stripe applied.

Putting the Rat away again until next time. Good visible progress.
December 2007

Finished front panel and applied FIAT racing stripe to radiator grille.

Front panel finished apart from indicators.
March 2009

Mainly electrics and painting this trip. Got all the back lights working and finished and painted the car silver and black. Is now in it's final colour scheme minus some vinyl graphics which I'm going to have made for it.

Rear lights fitted and working. Also boot and cab painted.

Front finished with indicators now working.
July 2009

Some small electrical and interior jobs this time. Not too much visible progress.

Dashboard is coming along nicely.
September 2009

Going backwards! Dashboard out again and front wiring loom removed. Some small progress in other areas though, mainly interior.

New centre console constructed.
October 2009

Interior panels constructed and fitted. Passenger side indicator repeater fitted into side bodywork.

Cab inside rear panels finished.

Constructing cab side panels and aluminium floor strip.

Constructing side repeater panel.

Side repeater fitted in bodywork.
December 2009

Exterior detailing, electrics and fitting new seats due to the old ones being ruined.
March 2010

Acquired a trailer for transporting the Rat which needed work. Got lots done with the wiring and interior and fitted the doors.
May 2010

Finished work on the trailer and some small cosmetic jobs done on the car. Trailer loaded and tested before transporting the Rat to it's new home is Wales.
June 2010

First time worked on at it's new home. Just a small job of drilling some drain holes in the boot floor to stop it filling with water.