David's Build Thread
 

Hello guys, Just a quick one to let you know I have started my build today. I collected my completed MX5 based chassis and wishbone pack from Saturn today and I am really pleased with it. A couple of hours spent in the garage using the vice to push the suspension bushes in and i am well under way!!. I have already gathered together a selection of mx5 bits over the last few months whilst I was waiting for the MX5 variant to be launched. I will initially put in a 1.6 engine and have a limited slip diff as well.

I have tried to upload some pictures but I keep getting an error message saying the file size is too big! Once I have worked this out I will post the images.

David

Good luck :)

and have fun.

Upload the photos to something like photobucket, you can then link to them rather than uploading them to the forum.

TT

Good luck with your build David, you,ll soon have it at the rolling stage & sitting in it going "brum brum" :D

keep us posted on your progress:cool:

cheers
andy

Ahh...so it was your chassis I was poking* about when I was up at Saturn last weekend :D It's very nicely made.

If you're collecting bits off different MX5s, make sure that the driveshafts and prop match your diff - they're different between the 1.6s and the 1.8s.

*Oi you - at the back there! Stop sniggering! :D

Thanks for the motivating messages. I have been getting all my mx5 parts from 1 source. Its a company that race mx5's so they have been giving me a few tips for further down the line!

You may have to share that source of parts with me lol

AK Automotive in Rowlands Gill. He sells a lot of stuff through ebay and is a big supplier to MNR for their MX5 variant.


I have now added a Flikr link so I can upload photos!!!

Looks Good :)

TT

you should be able to post the picture directly on the forum, should be some options under the share menu at the top of each picture.

TT

Something like this ( under share menu above photo, then get link)



Edit: get can't add the link on iPhone, right click on image, click on 640x480 size, then right click on photo copy image location.

Hope that helps

After lots of measuring, re-measuring and a bit more measuring I cut the aluminium for the floors over the weekend. An engineer friend of mine said he would do it for me but he has been on the sick so I had to do it myself. I am now ready to drill the first hole in my chassis which seems a little daunting!!.

I have put some pics on my flickr accounts.

Also does anyone know the size of the bolts used for the rally design alloy steering rack clamps... are these UNF. I have only just worked out Metric bolts!!

A floor transforms the look. Enjoy fixing it in place.

TT

Standard M8 metric bolts will be just fine for the rack clamps

Just make sure that they are at least 8.8 grade tensile strength ;)

Can't remember the length but long enough for a flat washer on top of the clamp & a penny washer underneath the rack support bracket, then nylock nut & leave a few threads spare :)

Hi David,

That's looks nice laid out in the garage, need anything then just give us a shout.

Cheers........AndyH

thanks Andrew - I am aiming to pop over on friday morning... be ready for lots of questions lol

also... tonight I had a riveting time!! I managed to get one of the floor panels in place. I got my wife to pur the first rivet in which she seemed to enjoy but she didn't volunteer to do the rest. Now I am just wondering how to get black sikaflex off my fingers and from under my nails!!

Don't get it on in the first place.... ;)

What type of riviter did you use? I used a lazy scissor riviter and it was a breeeeze.

TT

Cutting your fingers off would be the easiest way!

Its almost as bad as ford sump sealant :D

But a quater of the cost of the ford stuff..:eek:

I remember when I was doing mine, my 6 yr old (as he was then!) was helping, all I kept saying was "Keep away from that black stuff, if you get it on your cloths your mother will kill us."

TT

TT I have one of those lazy riviters as well and they make light work of all those rivets! now the floor is complete! (and i wore rubber gloves this time so no black fingers from the sealant!)

I have added some more pictures to my flickr account. The front end is assembled and looking nice. Notice the way I am using string instead of springs to save weight lol!

I have spent a little more time on my build and broke my first bit! I was tightening a bolt on a brake pad carrier and it snapped off. This mean't I had to go to AK Automotive (MX5 specialists) in Rowlands Gill for a new one. The fantastic thing is he tried to remove the broken bolt but it was well and truly stuck so he gave me a new one!! FREE. He also gave me 4 space saver wheels FREE of charge so that I can get it rolling! (on the understanding that I wont take them back to him as he has been trying to get rid of them for a while). All I need to do is get my mate to push me down the street and I will have a two seater go kart!!

Ive just spent the best part of the evening trying to drill out the top of my rear uprights with a 12 mm hole. If I manage to finally get through without killing my new bench drill it will be a miracle. Once this is done my chassis will be rolling!

All the bits I thought would be easy turn out to be hard work and the bits you think will be hard are easy! AGHH

Looking good David!

Not trying to teach you how to suck eggs, but if the drill is sharp, the speed is correct and its in a pillar drill a 12mm hole would take about a minute! even with no pilot hole

Good drills are worth their weight in gold if you are using cheapies by the way :)

thanks for the advice. I managed to get through eventually. Probably a mix of cheap drill and drill bit.

i now have my rear end assembled and two wheels on (well space savers)

I have put some more pics on my flickr acct.

Tomorrow as long as it doesn't rain I will push it out of the garge for the first time!!!

Its great when its on wheels and you can push it out of the garage and get some space back!

My arm now feels like it is going to drop off!
 

Just had a very productive night in the garage. Apart from it being freezing and windy I managed to cut the 5mm plate (with a hacksaw - i'm far too soft to use an angle grinder lol) for the gearbox mount and part of the 3mm plate for the handbrake (pictures on my Flickr link below)

Does anyone know how to post pictures into the message??

Something like this is what you need. With plenty of WD40 and a slow drill speed. Cheap drill bits are made of cheese!

http://www.screwfix.com/p/dewalt-12m...rill-bit/31989

Liking the nice clean garage and build up photos.:)

Dorma bits are really good too, they stay sharp forever, even with abuse, they are expensive but can be bought as single bits in the sizes you need for a few quid each.

I've been drilling through stainless rod with the ones you gave me Nathan and they have been spot on. Cheers..

AndyH

forgot to say, the rrp on those is £5 each so if i give you them half price i reckon you owe me about 500 quid:D :eek: :D give or take fifty quid or so.
Joking aside, i drilled through some 15mm hard plate on the stumpgrinder at work this morning, i couldnt be arsed with slow and steady cos it was in a hard to reach position. The bit was smoking like mad at full speed but went through no problem, it didnt blunt it a bit.

welding help needed
 

Is there anyone near Newcastle who would be able to weld a couple of brackets for me in exchange for some beer. I have been waiting for my mate who works offshore to do this for me ( a professional welder) however he has gone totally AWOL!! and im kind of now stuck with my build. There are 3 brackets . 1 gearbox mount, 1 diff support and a handbrake cable support. I can photos if required

Thanks

David

why dont you pop down and see spud, il be there on saturday so i could help if hes busy

huge thanks to spud for doing the welding that needed to be done on my handbrake and diff mount bracket. I also got to learn a bit about GRP from Noel. I have added some more pictured on my flickr account. More to follow...

handbrake all fitted in now
 

rear calipers (MX5)
 

I just picked up some rear calipers for my build. A bargain (I hope) from ebay. I have a had a look over them and started cleaning them up but...... I moved the handbrake attachment to see if the piston moved (on both calipers) and they didn't move. The levers move but the pistons didn't really budge. Does anyone know if the rear calipers rely on being full of brake fuid before they move. ie is it a form of hydraulic handbrake? I dont think there is anything wrong with the calipers. They seem to be in visual conditions. Thanks David

I popped in to see Nathan at NTS today and very kindly wwelded up my steering column. pictures on my flickr page.

What size of steering wheel are people using on their cars?

I managed to get hold of a cheep steering wheel from the supplier I normally get my mx5 bit from. No good for IVA but handy for pushing the car in and out of the garage. I also got a free copy of complete kit car magazine thrown in by him as well.

I have also got my rear aluminium panel in place without getting my fingers covered in black sikaflex

some more pics on flickr!!

A bargain and a new arrival!
 

After wondering about how to get a round having a Q reg my prayers were answered when Lancia John put up for sale his dismantled MX5 on here last week. I now have a garage full of mx5 parts and the identity to go along with it. I really only needed the endging and the loom so have lots of other parts available which will probably go on ebay. If anyone needs anything drop me a line and you can have it for a very reasonable price.

My build is going to go on hold for a coupe of weeks as my Daughter was born on tuesday morning so every spare second is going to involve sleep for me!! :)

Nathan at NTS, I haven't forgotten about the pedals and will be ordering asap still.