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. 

What You Will Need 
Brake piping 3/16 Kunifer two rolls for running the length of the car and cross over to wheels and servo.
Tube size may vary according to engine installation.
Brake Flaring tool.
Brake pipe clips for securing pipes to chassis.
Pop rivet gun, Pop rivets for securing clips to chassis.

Re-New
Brake Discs, Brake Pads, Brake Drums, Brake shoes, Brake Hoses, Brake Calipers, Brake Nipple Connections, Brake Cylinders, Brake T piece.
Consider, Brake Master Cylinder and Servo. 
All parts available from your local motor factor.

Brake Pipes must be secured to the chassis at a maximum distance of 12 inches apart. Many builders select a distance of 8 inches apart, well within the distance allowed.
Where a pipe run takes a bend, it is advisable to secure the pipe just before the bend and just after the bend.

Handbrake Cable
First fit the handbrake cable as described in the manual. Remember to locate it in the JBA handbrake brackets on the JBA chassis and not the Ford Sierra brackets on the sub frame.
JBA normally use a Partco cable, keep a note of this part number from the bag. Use it if you ever need to replace the cable in the future.

DOHC engine models with Fuel Injection have a different fuel pipe run which is also on the offside chassis rail, the fuel tank also has the filler neck on the offside. Remember to take this into consideration when preparing the brake pipe run on your chassis if you are using the DOHC fuel injection engine.

Fit all your new brake discs, drums and other parts to the axles. Then start on fitting the brake pipes.
Fit the brake balance valve into the plate on the inner offside chassis rail and the T piece to the rear of the inside of the chassis in the JBA location point. Follow the instructions in the build manual and use these photos as a guide.
Measure the distance between the two and cut a length of brake piping a little longer to a allow for the curve into the balance valve.
You will now need to flare this pipe  Firstly put your new connection nipple over the pipe and double flare it with a flaring tool, then bend it and fit into valve and secure with nipple. Remember not to flatten the pipe, if you don't have a bending tool, many household items can be used to bend it around. Some examples are shaving brush, salt dish, deodorant can, use an object of the size that you are trying to achieve with the pipe. 
Now run the new brake piping along the offside of the chassis, drilling small holes and pop riveting pipe clips to the chassis, remember that these have to be fitted to the inside of the chassis. Not the outside or underneath. Put a connection nipple over the other end of the pipe, then double flare it and connect to the T piece. 
The T piece is used to distribute brake fluid to offside and nearside rear wheels along with the flexible brake hoses.

Photo taken at Factory

Follow the instructions in the build manual
Continue from the T piece and add a length of pipe to the rear JBA pipe bracket, couple a new flexible brake  hose from this down to location on rear Ford Sierra sub frame. Make up another new pipe and connect from here to offside rear wheel cylinder, securing it with the existing Ford clips in the Sierra sub frame.
Next make up another pipe and run this from the T piece across the rear of the JBA chassis to the nearside rear pipe bracket and continue by adding the flexible brake hose in the same manner together with the brake pipe to the wheel cylinder.

Photo taken at Factory

Front Chassis
Now onto the front part of the chassis. You will not be able to complete all of this until the engine, gearbox and CBU have been fitted. However it is easier to do the pipe run before the engine is in place.

I will start in reverse order here.
Couple up the new flexible brake hoses from the front wheel cylinders on each wheel to the the location points on the JBA chassis. 
Then there are three pipes to make up here, but you can only flare one end at this stage. You have to allow extra length of pipe that will eventually reach and curve onto the master cylinder. Either flare and fit from the brake pipe roll or measure and then cut and flare and fit.

Photo taken at Factory

Now fit a connection nipple to the brake pipe roll and double flare end, fit to nearside front brake flexible hose and follow it round and across the front of the chassis as per manual and the photo above, securing it in position with pipe clips, pop riveted to the chassis. Take it along the inside offside chassis rail securing it as you go along towards the brake balance valve. 
Then allow enough length to reach and curve into the master cylinder, cut off pipe from roll and tape up the open end. Repeat for offside front brake and the other connection on the brake balance valve.

Once the CBU and the servo and master cylinder are fitted you will then have to put a connection nipple over these three pipes, remove the tape and double flare the ends, bend them and fit, then secure these pipes to the CBU.

This photo gives an idea of the amount of pipe leading from the chassis up to the master cylinder.

Below are the normal settings with a standard Ford Sierra. Always check the build manual and Haynes manual for the model you are using.

1 The front pipe on the Servo/Master Cylinder nearest the radiator which sits underneath facing down to the ground couples up to The Off Side /Front Brake Drivers side.

2 The middle pipe on the Servo/Master Cylinder which sits facing towards the passenger side couples up to
The Near Side / Front Brake Passenger side .

3 The rear pipe on the Servo/Master Cylinder nearest the windscreen which sits facing passenger side couples up to
The Brake Balance Valve.

You can move these three pipes out of the way by bending them carefully, when you come to fit the engine, gearbox and CBU. 

Speedometer Cable
If you are going to use a Speedometer with a cable drive, it is easier to fit the cable at the gearbox end now, rather than wait till the CBU is in place. 
However if you are using different size wheels than those on the donor car, change the speedometer drive in the gearbox. 
In my own case I also changed the speedometer drive in the gearbox as we would be fitting 15" wheels. The drive we used was a Sierra Cosworth available from any Ford dealer. The Cosworth uses 15" wheels.

The next page deals with fitting the Fuel pipes and the Petrol tank.

   Additional Photos Courtesy Doug Philp.

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