TOOLS YOU NEED TO ASSEMBLE THE KIT:

Only very basic tools are needed to assemble your Zero kit. You probably already have most of the required tools in your workshop, and need to purchase only a few affordable specific tools to construct the car. The kit can be assembled with hand or pneumatic tools; the latter requires less work, however you need an air compressor and this will add to the overall cost of your kit if you don’t already own one.

Note: You do not need to purchase all the tools below. For example if you have an electric drill you will not also need a pneumatic drill.


TOOL LIST

Electric Hand Drill:
You'll need a standard "hardware store" electric hand drill. Preferably, use a variable high-speed drill (2,500+ RPM), which makes drilling quicker and easier. It is an advantage that the drill is as lightweight as
possible- you will be using it constantly for rivet holes.
Hint: Place a Rubber Washer at the drill bit shank - this way when you drill through a hole, the rubber washer will protect the material from being dented by the steel "chuck" of the drill.

Pneumatic Drill:
If you have a compressor then purchase a standard pneumatic drill.



Drill Bits:
You'll need a number of drill bits, so get a few of each. Quality bits will stay sharper longer (making drilling easier).

TABLE OF SIZES

DRILL SIZE DRILL NUMBER RIVET/BOLT
3.2mm 3.2mm Rivet
10mm 10mm Bolt
12mm 12mm Bolt
4mm 4mm Rivet
6mm 6mm Bolt
8mm 8mm Bolt
½’’ ½’’ Bolt


Measuring Tools:

The Zero has been designed using metric measurements. For this reason we recommend that if you are not familiar with metric measures we recommend you purchase measuring instruments that have both imperial and metric measures.

To assist in building your kit it is useful to have the following:
• 10-12 Foot Tape Measure
• Steel Ruler
• Spirit level
• Plumb line (can be as simple as a weight attached to some twine)
• A Square

The spirit level and plumb line will be useful to assure that your workbench is flat and level, and to make sure that your parts (assemblies) are straight and level.


Hand Hacksaw:

A simple hacksaw with fine teeth (24 teeth per inch) is required to trim some items. If you have a band saw, you can use it instead of the hacksaw.


Hand & Pneumatic Riveter:

For riveting, you only need a simple hand riveting tool or a pneumatic riveting tool (for ‘pop’ rivets) if you have a compressor. You do not need a pneumatic riveting hammer and bucking bars, as only blind rivets are used (that means that riveting is very easy, quiet, and only a one man job). If you don’t already have a "pop" riveter, purchase a lightweight good quality model that will take the appropriate rivet sizes 3.2mm to 6mm.

Note: If you are using a pneumatic rivet puller you will also more than likely need a hand riveting tool as the pneumatic riveting tool is large and will not fit in small spaces.

Sheet Metal Snips:

Good sheet metal snips make cutting and trimming sheet metal nearly as easy as cutting paper. (Sheet Metal Snips (left and right)) it is easier to have both a pair for left-hand cuts (Red Grips - M1) and a pair for right cuts (GreenGrips - M1). Both pairs will also make straight cuts.


Hand File:

An assortment of small files for de-burring and filing edges is required.
Use sheet metal or "machinist" files, with a "smooth cut."
• Flat
• Half Round
• Round files


Other Tools:

For building the complete Zero kit, you will also need the following:
A set of standard wrenches / ratchet set
Spanners
Screwdrivers, etc
Hammer
wire crimpers
A bench vice (Small Clamp)
Pliers (maul grips)
Small angle grinder (slitting discs, and flapper wheel)
Sealant gun
Clamps
Knife

Note: It is not necessary to have professional quality tools as the work load for them is very small.
Hint: If you don't already have a specific tool, see if you can borrow one.


Tools You Don't Need To Assemble The Kit are:

A bending brake
A sheet-metal shear
Welder
A press, and so on


All major bends and cuts have been made to the materials provided in the kit, all welded parts are supplied "ready to assemble"


More Information & Where To Buy Tools:
Machine Mart do a good range of tools you can also try the DIY sheds like B&Q which often stock a good variety of tools.

Through out your build and ownership of your car we offer technical support and backup, via either telephone or email with our technicians. We can also off pre SVA inspection and general check of your car to ensure you get the best from the car.