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Steve Church Gives a Progress Report on his 1973 Sonett

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Last Updated: Mar 26, 2006

3/25/2003

After receiving very gracious and generous financial support from Viking Automotive, Gaithersburg, MD, I’ve been moving slowly but surely forward with important safety upgrades on my 1973 Sonett. Plans are still 'on track' for me to compete during the 2003 historic racing season.

One of the major upgrades is to replace the existing simple, plastic fuel bladder with an FIA-approved fuel cell -- a requirement for almost all forms of road racing. Included in this improvement effort is the design and construction of a cage made of ¾" square steel tubing to support, suspend and protect the fuel cell. In addition, a solid metal bulkhead must be built to completely isolate the fuel cell from the driver’s compartment.

To date, I’ve bought a slightly used Fuel Safe 8-gallon fuel cell with an aluminum container. The fuel cell cage is constructed, painted and mounted in the trunk. The measurements for a metal bulkhead have been passed to a local fabrication shop for custom bending of aluminum sheeting. I wanted the bulkhead job to look first-rate, and only a metal bending brake can produce the desired results.

Several other important jobs have been completed or are progressing:

  • A battery power cut-off switch has been purchased and installed, and the battery cable re-routed to and out of the switch. A metal bracket was fashioned from steel angle iron and welded to the existing roll cage behind the passenger-side A-pillar and above the door. The switch is easily accessible from outside the car, as required by competition rules.
  • A seatback brace has been designed and fabricated using steel angle iron and ¾" square steel tubing. Modern rules require that a seatback brace be added to an aftermarket seat to minimize the possibility of the seat breaking away from its floor mounts. Like any other brace of this type, mine attaches to the roll cage tubing at the rear of the driver’s compartment, and is bolted to the rear of my aluminum racing seat. It wasn’t an easy job building a brace that accounted for the curvature of the seatback, added support for the headrest (my headrest was weakened when I cut material away to give my shoulder harnesses much needed room), and tied into the roll cage in a mechanically-logical way. Then, the order of the fabrication was important for the final unit to come together successfully.
  • A driver’s-side window net has been bought and the mounting system partially constructed. The bottom mount is an aluminum rod that passes through the base of the net and two steel end tabs. The rod isn’t meant to be removed often, so ‘hairpin’ clips keep it in place in the tabs. The mounting system for the top of the net hasn’t yet been designed. This is the part of the system that’s removed every time the driver gets into the car, so a spring-loaded or latched rod system is required.
  • The majority of my stickers and decals were stripped off the car.
  • A 2.75-pound, BC dry chemical fire extinguisher w/metal mounting bracket has been purchased but not yet installed.
  • My six-year old 5-point racing harness was traded in for a brand new SafeQuip unit that was custom-designed for the small dimensions of my body and the limited dimensions of the Sonett’s interior. SafeQuip harnesses cost little more than other high-quality harnesses, and they’re hand-made in America, so you can talk directly with the builder if you have unique requirements.

There are several more small projects, and one big project, yet to be completed. More on these in a future report.

Steve

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