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-   -   Loony's BEC Roadster Build Thread (http://www.haynes.co.uk/forums/showthread.php?t=6165)

loony 26th March 2011 02:31 PM

Loony's BEC Roadster Build Thread
Maybe it's to early, but to keep forum clean I decided to create my build thread.

Beginings where similar to everyones here.
First I bought the book "Build your own sports car: for as little as 250GBP" on ebay.co.uk. Book costs 0,99GBP and 5GBP p&p :) It was about 2 years ago...
I realized that it will be very difficult to find parts mentioned in the book here in Poland. So... I need something for more popular Ford Sierra.
Next - in August 2010 - I bought "proper" book... and so it begins.
I choose BEC because I want something different than my last project (powerfull but heavy - turboed '93 BMW 325i). Must be lightweight and... with better economy - cheap insurance, good MPG. So "under 1000cc" BEC will be what I'm looking for.
In October I bought Sierra rear end - propshaft, 3.62 LSD diff, driveshafts, calipers, rear hubs and front uprights. Then - to keep proper brake bias - I bought Mondeo Mk2 V6 front calipers (same as Scorpio/Granada Cosworth) to use with 278mm brake disks.

I cleaned rear calipers and painted with black Hammerite:

Now it's time for front calipers, uprights and rear hubs.

Yesterday I got my laser cut chassis plates (with modified front wishbones plates for use with Kadett/Lanos ball joint - Maxi is unavailable in Poland):

Next - I need Mig/Mag welder :)

james3004 26th March 2011 05:39 PM

Did you strip the calipers to paint them, cos I'm stuggling to work out how to pull them apart

flyerncle 27th March 2011 10:49 AM

If they work ok leave them alone and paint,they are a work of art to strip and repair.

james3004 27th March 2011 11:06 AM

I want to powdercoat them, and the need de-rusting :(

ozzy1 27th March 2011 01:58 PM

I wouldnt bother stripping them just send them to these guys :D


loony 27th March 2011 04:37 PM

Yes - I was stripping them to repair handbrake and then de-rust and paint. It was quite difficult, but now they work nice and smooth.
Look at photos in this topic - it's in Polish, but photos are multilingual ;) http://www.audi80.pl/90-b3-ng-regene...yl-vt44458.htm

loony 16th November 2011 10:55 PM

It was quite a long time I wrote, but I have to change my as you call it "daily driver" (Ford Escort 1.8TD with camshaft belt broken), so... roadster have to wait... (cruel world).
I bought a "new daily driver" - Opel/Vauxhall Frontera 2.2DTI 2002 (Polish roads are terrible) and... now I have some debts to pay (I already paid a part borrowed from my brother, but there's a second part borrowed from my parents).

But... I didn't give up. I bought MIG welder :) - 0% installment purchase ;)
It's a Bester 1700s (by Lincoln Electric) - 160A max - so it should be good enough to weld Roadster ;)

Now - I'll practice welding by creating dog guard and roof rack...

loony 18th February 2012 08:23 AM

Last news - I'VE GOT ENGINE ! (Sorry - I'm little excited)

Yesterday evening I was on the "trip". I bought 2003 ZX9R engine "package" for about 436.
Package contains everything I need (or I think so): engine, carbs, complete wiring loom (CDI, relays, fuses, etc.), airbox, exhaust manifold, radiator with fan, fuel pump... and damaged clocks ;)
I'm really happy. I'll post better photos when I find someone to help me take engine out of my trunk ;)

Now, I can start real building of a car :) Time to weld chassis...

loony 2nd April 2012 06:42 PM

Last progress...
I have my laser cut reverse gear... I hope it'll fit in transmission tunnel (156mm diameter)

Mushrooms made of steel (but cost me about 12GBP):

loony 2nd April 2012 06:43 PM

And parts of sprocket adapter (laser cut 20mm steel donut and turned ZX9R sprocket):

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