Today's fun and games...

In spite of yesterday's optimism, when we tightened up all the nuts
and bolts on the front suspension, the wheels locked. Turned out to be
a combination of things, but mostly the brake carriers wanted to be a
part of the discs when the hub nuts were tightened up. That required
some careful tickling of the hub and the carrier but that's now
resolved. Fitting the wheels with the spacers - they're too thin to
have hub centres - is a pain but we managed, and the Focus wheels self-
centre on their cone washer bolts.

At the back we discovered the panhard rod which controls the rear
track was fractionally short; it meant the passenger rear wheel jammed
against the trailing arm on full droop. This hadn't been an issue with
the narrower tyres, but with 195s it's a problem (and possibly with
the 185s I'm planning on using) so we fixed it by cutting the rod and
TIG welding it back two(!) millimetres longer... Now it's clear, and
using 185s will give another 5mm clearance all round.

We've fitted the gearstick and cables; it takes quite a while to get a
hole-saw through half an inch of fibreglass...

And finally, we've made a test fit of the dashboard; the instruments
will go in with a little persuasion but the steering wheel still has
us scratching heads; it's the same length as the Ford item but starts
three inches nearer. We thing we have a solution but will consider in
daylight when we've had a chance to sleep on it.

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