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Author: Subject: Distilled IVA Manual
G13BLocost

posted on 7/4/19 at 07:59 PM Reply With Quote
Distilled IVA Manual

Worst, book, ever.

For the last two months, before I go to bed, I have been trying to read a little bit of my printed copy of the IVA manual. Its been a slog. Its covered in post-it notes addressing all the little things I need to consider for making my car roadworthy. I have typed up this list and I am going to copy it here for anyone who doesn't fancy reading the manual or needs a quick reference.

Any comments are welcomed, I have never IVA'd a car before. To be honest I sway between utter relaxation about the whole thing and complete unending dread. No wonder no one wants to build kitcars anymore, this process is insane!

Side note: my car doesn't have a heater or windscreen, so there are bits I skipped over. I also have a pre-95 engine so need some form of proof of age.

• Vehicle Class A – Ameteur Build Basic IVA
• Must have VIN number pre-IVA
• Exhaust must have no leaks (no pin holes etc)
- Must achieve 99dBA @ 500mm distance from exit
- 2/3 of max quoted power = 6500 * 2/3 = 4360 rpm (Suzuki G13B)
• Proof of engine age – Requires documentation
- Old VIN plate from donor car [HAVE]
- Letter from DVLA with copy of V5 [HAVE]
- Picture of engine number / access to engine number [HAVE]
- Emissions, CO <= 3.5%, HC <= 1200ppm, At normal idle, At running temperature
- Proof from Suzuki (manufacturer)? [QUESTION: DEFINITELY REQUIRED? IS ABOVE FROM DVLA ENOUGH?]
• Fuel tank must have ground strap
• Bulk head must have no holes
• Fuel drain must flow outside vehicle and as well as fuel tank vent
• Fuel cap must be tethered or locking
• Rear registration plate must be vertical
- Do I need an IVA test plate? [QUESTION]
- What height should this be at?
• Steering system must not foal anything lock to lock
• Steering must self centre at 10mph
• Steering limits must be part of design (i.e. under the grease boots)
• Needs to EC Type approved horn or equivalent
• Must have driver and passenger mirrors
- Mirrors must be adjustable
- Need to replace rear view with adjustable mirror; must be reachable by driver with the seat belt disengaged
- Mirror mounting positions are bloody confusing
• Handbrake must be usable with one hand on the wheel and must have at-least one click achievable
• Brake pedal must have anti slip tape
- Ensure brake pedal doesn’t hit fire wall at full travel
- Ensure brake pedal doesn’t creep downwards when held
- Balance bar needs locking wire
- Sticker required near master cylinder explaining type of fluid; DOT 5
• Handbrake cannot move when knocked left to right
• Handbrake must have spare clicks in both directions (adjustable)
• Brake reservoirs need level switches
- Handbrake switch can be used to check brake level light with ignition on; no handbrake light required specifically
• Front axle should lock before rear axle
- The brakes shouldn’t rub when rolling in either direction
• HT leads must have suppression markings (i.e. manufacturer leads)
• Lots on interior radii; blah blah
- 127mm exemption zone around steering wheel
• Car must have steering lock or immobilizer
• No car alarm required
• Steering wheel tested with 165mm diameter ball. 2.5mm radius minimum
- Pad current wheel or use a stock wheel (fiesta)
- Prove that chassis is crushable ahead of steering rack?
- Prove angle of steering rack is 10deg>
- Prove car has collapsible column
• Trim seat edges
- Buy seat trim from JK Composites as car requires a head rest of a given stiffness
- Ensure head rest is at correct location and size (700mm above seat block)
• The exhaust needs to be wrapped to pass radius rules
- The floor line needs a 2.5mm radii (rubber or aluminum trim?)
- Exterior mirrors are free of radii rules
- The exhaust must not hang more than 10mm below the floor and must have a 2.5mm radii on the exit
- Inside of wishbones is exempt from exterior projection rules
- Middle of chassis rail is line between interior and exterior projections
• Use speed lookup table to tune speedo. Must over read by given amount.
- Speedometer must be visible at all times and positioned on the dash so that is the case
- Intervals on speedo must be 20mph or less
• The car must have a manufacturer plate
- The VIN must be stamped on the right hand side (drivers) of the chassis in given size
• Seat bolts need 100x100x4mm spreader plate, with 8.8 or better bolts
• Seat belt mounts must pass visual inspection [ARE PICTURES GOOD ENOUGH?]
- Show proof of 7/16 UNF bolts
• Lights are positioned by the closest point of the reflective surface
- Separation is based on minimum distance of reflective surfaces
- Using a given lamp should not dim another lamp
- Ensure lights pass visibility angle rules [ARE FRONT INDICATORS A PAIN?]
- Does dashboard lighting count as rear projected white light?
- Pair of rear reflectors required- best to get light pods with them built in
• Tell tales should…
- Be on the button or separate (just visible)
- They need a word description or a picture
- Position lamps / side lamps must have a tell tail (dashboard lights count)
• Front headlamps, 400mm max from outside of car, 250mm min from ground (but 500mm from later rules in book)
• Rear headlamps, 400mm max from outside of car, 350mm min from ground
• Indicators must have a tell tale
• Hazard lights must have a tell tale
• Hazard lights must work with ignition off
• Indicators, 400mm max from outside, 350mm min from ground
• Must have rear number blade lights (come on with position/side lights?)
• Main beam (I call them high beams…) must have tell tale and it must be blue
• Headlights must be aligned specifically to the rules in the manual
• Repeat, headlamps must be 500mm!?! off the ground
• Rear fog…
- must be positioned to the offside (passenger side)
- must have a minimum separation from brake light of 100mm
- only emit red lighting
- come on during dipped / main beam, and not turn back on afterwards
- must have a visible tell tale lamp for driver
- must be more than 250mm from the ground
- must be vertical to the rear of the car (within what tolerance?)
• Reverse light
- Should turn on when in reverse
- Be 250mm from the ground
- Emit white light
- Thats it!
• Harnesses must…
- Either be BS3254 or FIA 8853-98 standard
- Upper anchor must be 450mm above the reference block
- Lower anchors must be more than 350mm apart
- Must be over 46mm in width
- Adjusters must be accessible to users (I don’t know about my side adjusters…)
• Wheel guards must be 30deg forward and 50deg rearward of vertical plane
• The rear of wheel guards must be below 150mm above centre wheel plane
• Vehicle must have calculated maximum design weight
- There are a whole bunch of rules about gross and design weights…
- Calculations must be provided
• Tyres must have E, ‘e’, DOT or JIS marks
• Tyre load and speed must be within that of the car
- Calculated maximum speed must be provided along with appropriate tyres being fitted
• General construction…
- Nothing should leak (duh!)
- All electrical cables/wires should be mounted at 300mm intervals or less (not fuel pipes?)




[Edited on 7/4/19 by G13BLocost]

[Edited on 7/4/19 by G13BLocost]





Between Building Robots, Building Cars, Playing D&D and Walking Dogs, I have no time at all!

Long time car builder and ex-F1 engineer; no silly questions please.

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macc man

posted on 7/4/19 at 09:14 PM Reply With Quote
I have to take my hat off to you for your labours to compile this list. I can see how the amount of work
needed to IVA a car would put most folk off. Best of luck with your build.

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melly-g

posted on 8/4/19 at 06:26 AM Reply With Quote
That's quite a list! Well done for having the patience to do that.

I'm not reading through all that again, but I didn't notice anything about day time running lights (DRL)?

They are required now aren't they?

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loggyboy

posted on 8/4/19 at 10:23 AM Reply With Quote
quote:
Originally posted by melly-g
That's quite a list! Well done for having the patience to do that.

I'm not reading through all that again, but I didn't notice anything about day time running lights (DRL)?

They are required now aren't they?


Nope

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Edwardo

posted on 8/4/19 at 12:56 PM Reply With Quote
quote:

Fog Lamp - must be positioned to the offside (passenger side)



Offside is drivers side for UK RH drive car.

Cheers
Tony

[Edited on 8/4/19 by Edwardo]

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shindha

posted on 8/4/19 at 01:58 PM Reply With Quote
Can this be made a sticky??
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G13BLocost

posted on 8/4/19 at 06:37 PM Reply With Quote
quote:
Originally posted by Edwardo
quote:

Fog Lamp - must be positioned to the offside (passenger side)



Offside is drivers side for UK RH drive car.

Cheers
Tony

[Edited on 8/4/19 by Edwardo]


Oohh can I get a witness before I drill holes in my back panel please? I had a look at some cars in the street and it would suggest your correct. Red fog light, drivers side .





Between Building Robots, Building Cars, Playing D&D and Walking Dogs, I have no time at all!

Long time car builder and ex-F1 engineer; no silly questions please.

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gremlin1234

posted on 8/4/19 at 07:33 PM Reply With Quote
quote:
Originally posted by G13BLocost
Oohh can I get a witness before I drill holes in my back panel please? I had a look at some cars in the street and it would suggest your correct. Red fog light, drivers side .
its usual to fit fog, and reverse lights, as a
(un)matched pair.
so if you drill the wrong side, you're still ok!


[Edited on 8/4/19 by gremlin1234]

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loggyboy

posted on 8/4/19 at 11:08 PM Reply With Quote
quote:
Originally posted by G13BLocost
quote:
Originally posted by Edwardo
quote:

Fog Lamp - must be positioned to the offside (passenger side)



Offside is drivers side for UK RH drive car.

Cheers
Tony

[Edited on 8/4/19 by Edwardo]


Oohh can I get a witness before I drill holes in my back panel please? I had a look at some cars in the street and it would suggest your correct. Red fog light, drivers side .


Of course the offside is the drivers side. (Nearside) Side nearest the kerb is passenger.)

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G13BLocost

posted on 9/4/19 at 05:07 AM Reply With Quote
Of course





Between Building Robots, Building Cars, Playing D&D and Walking Dogs, I have no time at all!

Long time car builder and ex-F1 engineer; no silly questions please.

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CosKev3

posted on 9/4/19 at 08:17 AM Reply With Quote
Haven't read all of it,but couple of things I noticed:

Fuel cap needs to be a locking type that the key can't be removed from when the cap is off the car,not just a normal locking cap.

Car needs two items of security,so presuming you are using an ignition barrel?Key counts as one,then you either need a locking steering column or a immobiliser etc.

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40inches

posted on 9/4/19 at 09:06 AM Reply With Quote
quote:
Originally posted by CosKev3


Fuel cap needs to be a locking type that the key can't be removed from when the cap is off the car,not just a normal locking cap.




Mine isn't locking, but is tethered. Is that now not allowed?

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CosKev3

posted on 9/4/19 at 10:44 AM Reply With Quote
quote:
Originally posted by 40inches
quote:
Originally posted by CosKev3


Fuel cap needs to be a locking type that the key can't be removed from when the cap is off the car,not just a normal locking cap.




Mine isn't locking, but is tethered. Is that now not allowed?


No tethered is fine,I was just referring to the 'or locking cap' statement

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40inches

posted on 9/4/19 at 11:04 AM Reply With Quote
quote:
Originally posted by CosKev3
quote:
Originally posted by 40inches
quote:
Originally posted by CosKev3


Fuel cap needs to be a locking type that the key can't be removed from when the cap is off the car,not just a normal locking cap.




Mine isn't locking, but is tethered. Is that now not allowed?


No tethered is fine,I was just referring to the 'or locking cap' statement

Understood

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G13BLocost

posted on 9/4/19 at 12:20 PM Reply With Quote
quote:
Originally posted by CosKev3
Haven't read all of it,but couple of things I noticed:

Fuel cap needs to be a locking type that the key can't be removed from when the cap is off the car,not just a normal locking cap.

Car needs two items of security,so presuming you are using an ignition barrel?Key counts as one,then you either need a locking steering column or a immobiliser etc.


Yes! I have an ignition barrel and a steering lock

Good shout on the fuel cap





Between Building Robots, Building Cars, Playing D&D and Walking Dogs, I have no time at all!

Long time car builder and ex-F1 engineer; no silly questions please.

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FamilyGuy

posted on 9/4/19 at 07:27 PM Reply With Quote
Ref the fog light control not switching back on after lights are turned off. I was looking at this and I believe this is only a requirement if the fog light comes on with side lights. Looks like the wording in the IVA manual was updated to clarify this.

https://www.pistonheads.com/gassing/topic.asp?h=0&f=30&t=1357612&i=20

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G13BLocost

posted on 10/4/19 at 09:16 PM Reply With Quote
Nice to hear that you DON'T need to get a garage to check your VIN plate over if you are registering a Kit Car.

https://www.locostbuilders.co.uk/viewthread.php?tid=214635





Between Building Robots, Building Cars, Playing D&D and Walking Dogs, I have no time at all!

Long time car builder and ex-F1 engineer; no silly questions please.

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