Now in 2010 we do not  have a JBA Factory producing any vehicle that has been evaluated in any articles in the various Kit Car Press magazines or approved by VOSA BIVA testing.

Please note these are the old build pages from 1999 to 2004 when we had a JBA Factory in full production from 1982 that was regularly featured in the Kit Car Press and complied with regulations including passing UK Vosa SVA/BIVA tests and TUV tests in the EU.
A 2004 JBA Engineering Ltd Sports SR kit has passed the new BIVA test in June 2009.

Spanner Sizes
Spanner Sizes fits on the head of a bolt. 8mm spanner fits M5 bolt, 10mm......M6, 13mm......M8, 17mm......M10. 

Options
Paint it Yourself, Have a Friend to Spray it, Professional Job. 

What You Will Need 
See Text 

1993 Sports Photo

When we arrived at this part of the build I felt a bit saddened, after all the work it had to be stripped down. 
I felt like continuing with the interior, as the dashboard template had already been done, but with the car in blue covered aluminium panels and white gelcoat, it just had to be done.
It is a reversal of the build, removing the headlamps side lamps and rear lamps. Then the windscreen, doors, locks and hinges plus the six bonnet panels, four wings and the boot. 
We kept the bolts for each section in separate boxes.

My mate Mike Cushley painted his Tourer himself and it was outstanding in the two tone colour, but neither Kenny or I had the confidence to tackle the painting ourselves. 
It was a choice between putting it out to a firm or getting mates to spray the Falcon inside our garage. 
As I had a compressor we chose the latter, my mate from work Tam Thomson sprayed the undercoats and another mate Sammy Potter sprayed the top coats. Sammy lived in the next street and sprayed cars for a local firm. I did the rubbing down between coats.

We decided on a two pack paint job, the colour we chose was Porsche Guards Red. This involved buying the paint plus the base undercoat and an etch primer. Other things included were special thinners for two pack, mouth masks, masking tape, sanding block, various grades of wet & dry paper and a tin of "Farecla" this is a rubbing down paste for two pack paint, used on the final top coat. This does not dull the finish on two pack as it does not contain ammonia. 

The first part was to rub down all the GRP panels and smooth out the seams on the CBU, wings and rear light clusters with wet and dry paper and checked them by running fingertips over them, until I could not detect the join or feel any resistance. 
This was all done with the CBU and wings still fitted to the chassis, as it gives a stable base to work on, finally washing off all the car with clean water.

The next task was to remove all the aluminium panels and move the chassis with the CBU and wings out of the garage, then rub down the aluninium panels with wet & dry paper using soap and water, covering up the benches and open cupboards with polythene, as the overspray gets everywhere. 
My mate Tam sprayed them with an etch primer paint. It is only aluminium parts that need sprayed with this type of primer. 
If you intend painting the side screen frames these will need a coat of etch primer. 

We removed the CBU and wings and brought these into the garage, leaving the chassis outside.
Tam used a high build primer to spray on all the panels as the base coat, the wings were hung from the rafters out of the way with the CBU sitting on a table, so that we could bring the chassis in.
These were left for a few weeks until I had time to rub them down with fine wet and dry paper.

Sammy cleaned and prepared the panels for painting with the top coats. This was really good to see the all the panels in their final colour. 
It was a fortnight later before we started on the Falcon bodywork, during this time the stainless steel items were away for polishing and the chassis was given a good clean to get rid of all the dust. 
We started to apply the "Farecla" rubbing compound to all the panels and CBU, it is easier to use an electrical orbital polishing tool or a polishing mop on an electric drill, but you still have to do certain parts by hand. 
The CBU was fitted up again on the table, with the air intake, heater, steering moulding and all sealed in place. the washer bottle was fitted.

Chassis Check 
At the same time all the bolts and fixings on the chassis were checked, smeared with copperslip and tightened. The bolts on the rear dampers have to be tightened properly, if the are too slack this will give the car a wagging tail end, very noticeable when car is driven slowly in heavy traffic. 
The prop shaft was not fitted until the CBU and handbrake cable were in place.

1993 Sports Photo

The CBU was fitted to the chassis for the last time the handbrake was fitted and the cable connected up to it, then the prop shaft was fitted. 
As per build manual the CBU openings in the floor were sealed with silicon sealant, mechanical parts followed, brake servo, pedals, steering shaft etc. The brake pipes were connected up along with all the other cables, wiper motor and wheel boxes.
All the other body parts were fitted except the doors and windscreen, this was to allow easy access into the interior for fitting it out.
Rather than using the Nylock nuts supplied in the kit I had saved these for the final fit, I had used plain nuts during the build, fitting and refitting panels and wings. All the bolts were now smeared with copperslip and Nylock nuts fitted and tightened. 

1993 Sports Photo Non Opening Boot

All the exterior extras were fitted along with the Falcon scroll and all the lights and badges, nothing was wired up at this stage. 

Speedometer Sensors
Remember to fit the Speedometer sensors as detailed by your Speedometer supplier. The Speedometer dial must conform to the SVA regulations. See Doug's Page.
Greengauges supply useful fitting instructions on their website. 
Sensor Guide and Speedo Fitting Guide.

Do not fit extra items such as front spot and front fog lamps, interior sun visors or rear luggage racks etc.  until after the SVA Test.

Paint Suppliers
One of the biggest suppliers of Automotive Paints and related products is Brown Brothers, they can be found locally throughout the UK. 

The next page deals with the Dashboard.

  Additional Photos Courtesy Of Doug Philp.

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