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Author Haynes Roadster - self built from scratch.
Ste
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Registered: 5th Mar 03
Location: Taif, Saudi Arabia
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1st Aug 13 at 22:17   View Garage View User's Profile U2U Member Reply With Quote
quote:
Originally posted by willay
are you using filler at your desk at work mate?


yeah lol

I would rather lose by a mile because i built my own car, than win by an inch because someone else built it for me.
corsadonk
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Registered: 4th Jul 09
Location: Marlborough, Wiltshire
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2nd Aug 13 at 17:21   View Garage View User's Profile U2U Member Reply With Quote
Fair play for doing a bit every day.
SVM 286
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Registered: 13th Feb 05
Location: pain
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6th Aug 13 at 23:37   View User's Profile U2U Member Reply With Quote
Ste, did you kill a Sierra Twinc for parts?
Robin
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Registered: 7th Jan 04
Location: Northants Drives: Clio 182 Cup
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7th Aug 13 at 08:05   View Garage View User's Profile U2U Member Reply With Quote
Thought you were using a Saab lump, what's with the Sigma?
Ste
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Registered: 5th Mar 03
Location: Taif, Saudi Arabia
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8th Aug 13 at 04:20   View Garage View User's Profile U2U Member Reply With Quote
Robin, just decided to stick with the ethics of 7 building and go with a light engine. The saab ones are really heavy and the sigma is super light. Going to try super charging this one and look for 200 bhp

I would rather lose by a mile because i built my own car, than win by an inch because someone else built it for me.
Ste
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Registered: 5th Mar 03
Location: Taif, Saudi Arabia
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8th Aug 13 at 04:22   View Garage View User's Profile U2U Member Reply With Quote
quote:
Originally posted by SVM 286
Ste, did you kill a Sierra Twinc for parts?


Was a 1.8 Chasseur

I would rather lose by a mile because i built my own car, than win by an inch because someone else built it for me.
Robin
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Registered: 7th Jan 04
Location: Northants Drives: Clio 182 Cup
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8th Aug 13 at 09:07   View Garage View User's Profile U2U Member Reply With Quote
quote:
Originally posted by Ste
Robin, just decided to stick with the ethics of 7 building and go with a light engine. The saab ones are really heavy and the sigma is super light. Going to try super charging this one and look for 200 bhp


Sounds like a much better plan to me!-
Ste
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Registered: 5th Mar 03
Location: Taif, Saudi Arabia
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8th Aug 13 at 16:25   View Garage View User's Profile U2U Member Reply With Quote
Been on holiday this weekend just gone so less progress this week.

Fabricated and painted my roll bar. 50mm x 2mm wall seamless tube hoop with a 40mm x 2mm seamless harness bar across it. Into this I welded four threaded inserts for the harnesses.








Primed then painted with Plasti-kote gloss black. This stuff leaves a finish like powder coating.










Diff brackets welded up and painted as above but in satin black










Made the inserts for the suspension bushes. These are seamless stainless steel. 22 of them made then polished up.







Poly bushes inserted into the lower wishbones, then they were packed away till final assembly.










Custom alloy bell housing arrived so mated the trial engine and box




Then fitted it into the chassis to make the engine and gearbox mounts


















I would rather lose by a mile because i built my own car, than win by an inch because someone else built it for me.
SVM 286
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Location: pain
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9th Aug 13 at 03:35   View User's Profile U2U Member Reply With Quote
quote:
Originally posted by Ste
quote:
Originally posted by SVM 286
Ste, did you kill a Sierra Twinc for parts?


Was a 1.8 Chasseur


Carb'd CVH with EGR and a Cat? I can almost dig that.
Ste
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Registered: 5th Mar 03
Location: Taif, Saudi Arabia
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9th Aug 13 at 16:27   View Garage View User's Profile U2U Member Reply With Quote
Engine mounts today.

3mm steel plate and 50x2mm cds tube.

Mounts are Landrover Defender engine mounts £4.50 each. Bargain!
























All now painted. That's the chassis complete now. Next on the list of jobs is making a fuel tank and running fuel and brake lines etc.

I would rather lose by a mile because i built my own car, than win by an inch because someone else built it for me.
Ste
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Registered: 5th Mar 03
Location: Taif, Saudi Arabia
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12th Aug 13 at 01:54   View Garage View User's Profile U2U Member Reply With Quote
Mounts were primed and painted the other day so tonight I re-fitted the dummy engine and started a mock up super charger inlet plenum.

It uses half of the standard puma inlet with the threads drilled out and captive nuts inside the planum.

Bare in mind, this is a mockup to see how it fits so it is rough.

The finished item will be aluminium and have short trumpets on the inlets.























I would rather lose by a mile because i built my own car, than win by an inch because someone else built it for me.
ArdenblueDan
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Registered: 23rd Aug 12
Location: Basildon
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13th Aug 13 at 19:59   View User's Profile U2U Member Reply With Quote
Looking good buddy
Stu_22
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Registered: 25th Mar 02
Location: Luton
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12th Sep 13 at 09:37   View User's Profile U2U Member Reply With Quote
Any updates?
Chris F
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Organiser: East Anglia
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Registered: 26th Dec 05
Location: Newmarket Drives: Escort Van 1.8
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13th Sep 13 at 07:51   View Garage View User's Profile U2U Member Reply With Quote
This is awesome, how have i not seen this lol!
daymoon
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Registered: 1st Aug 08
Location: Selby, North Yorkshire
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12th Oct 13 at 13:26   View Garage View User's Profile U2U Member Reply With Quote
is it done yet?
Ste
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Registered: 5th Mar 03
Location: Taif, Saudi Arabia
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9th Dec 13 at 14:56   View Garage View User's Profile U2U Member Reply With Quote
Not been on it for ages or when I have I've not took pics.

Recently I've modified the steering column lower bearing to take a proper ball bearing as the standard Ford plastic one is causing no end of issues for IVA for lots of people.

This was a simple enough job








I've decided against the Ford 1.7 engine that was in there as there was too many issues converting it to a reliable RWD engine.

Instead, I'm probably going down the MX5 engine and gearbox route.

Started making the mounts for the radiator. It's a rad from a 1.2 Clio.










Not finished it yet as I wasn't happy with the welding quality on the thin steel tubes for the mounts so I'm scrapping them and starting over.


[Edited on 09-12-2013 by Ste]

I would rather lose by a mile because i built my own car, than win by an inch because someone else built it for me.
corsadonk
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Registered: 4th Jul 09
Location: Marlborough, Wiltshire
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9th Dec 13 at 17:41   View Garage View User's Profile U2U Member Reply With Quote
About time. Are you going for forced induction with the Mazda engine?
SteveoBC
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Registered: 22nd Feb 07
Location: Bucks
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9th Dec 13 at 20:40   View Garage View User's Profile U2U Member Reply With Quote
Some good fab work going on here, nice welds on the roll bar
Ste
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Registered: 5th Mar 03
Location: Taif, Saudi Arabia
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9th Dec 13 at 23:34   View Garage View User's Profile U2U Member Reply With Quote
quote:
Originally posted by corsadonk
About time. Are you going for forced induction with the Mazda engine?


I'm going to build it n/a but do a turbo conversion once IVAd.

There's a good video on youtube on mighty car mods where they turbod a mk1 mx5 and got some good results and it looked easy enough to do.

I would rather lose by a mile because i built my own car, than win by an inch because someone else built it for me.
corsadonk
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Registered: 4th Jul 09
Location: Marlborough, Wiltshire
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10th Dec 13 at 21:31   View Garage View User's Profile U2U Member Reply With Quote
I've always had a soft spot for a forced induction MX5.
Darryl H
Organiser: South Central
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Registered: 19th Nov 09
Location: Camberley Drives: Porsche 944
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10th Dec 13 at 23:13   View Garage View User's Profile U2U Member Reply With Quote
My dad used to turbo them when he worked at Mazda. He said the engines were pretty bullet proof

Fab work is awesome!

|My Corsa|SC|My Instagram|
Ste
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Registered: 5th Mar 03
Location: Taif, Saudi Arabia
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21st Mar 14 at 01:16   View Garage View User's Profile U2U Member Reply With Quote
Finally got round to re-starting work on the car after moving house and re-setting up my garage.

Made new rear wishbones and top camber adjusters then used my new compressor box to make a mini spray booth.

They were then fitted with the bushes and stored away.













I would rather lose by a mile because i built my own car, than win by an inch because someone else built it for me.
neil h
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Registered: 28th Sep 06
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21st Mar 14 at 12:59   View User's Profile U2U Member Reply With Quote
Well this is no where near what i expected when I saw the project name

Fair play for actually going out and building it all from scratch, i've got a copy of that book but wouldn't have the time/space/skills to actually build it.
Ste
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Registered: 5th Mar 03
Location: Taif, Saudi Arabia
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28th Mar 14 at 22:36   View Garage View User's Profile U2U Member Reply With Quote
Started stripping down the MX5 engine and cleaning and painting the parts.

Started with the cam cover

VHT wrinkle finish. Baked at 95C for an hour.










Ordered the bolts for the suspension so mocked up the rear wishbones and fitted my camber guage to see how it adjusts. quite happy with it.




I would rather lose by a mile because i built my own car, than win by an inch because someone else built it for me.
Ste
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Registered: 5th Mar 03
Location: Taif, Saudi Arabia
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13th May 14 at 22:39   View Garage View User's Profile U2U Member Reply With Quote
Not updated in ages because I'm a lazy bastard, but here's some pics



















I would rather lose by a mile because i built my own car, than win by an inch because someone else built it for me.

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