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 :)

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

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

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

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

http://biggred.co.uk/index.php

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

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...

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...

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):

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

Little update...
In October I made build table...


My little helper...




Then I brought steel

And the battle with chassis began...

Front frame




I'm not happy with the result - I think I will have to make one again... but I'll see how it fit to the rest of chassis.

But it's cold outside, I'm sick (some kind of flu) so I orginised my work different ;)

One guy from work has lathe, I draw some sketches and he did for me some parts:

Crush tubes, bush tubes... with DIY polyurethan bushes (I made them myself from two-component polyurethan resin)

It's just an example - I got whole set of them...

Front camber adjusters, sleeve tubes and rear camber tubes (?):


DIY sprocket adapter almost ready (SAE1140 flange)...


Need some welding...

... and then turning/balancing...

Tomorrow I plan to weld it but balancing/turning have to wait until water cooled lathe defrost and start to work again...
Next week I will have catalytic gas heater - maybe this would help keep me warm while building.

Looks like you have all the skills to make an excellent roadster:)

Looks good so far ,keep it up. The winter usually sorts the men builders from the boys:rolleyes:
You may need a nuclear power plant in your garage for Polish winters:D

Hoho, I think I recognize this layout :)
Good and rewarding to see that other people use it, and that this layout has not only been used once on my table. Still available from my Google documents

And it is still immaculate, it will not last :D

And by the way, you look to be doing a very good job, so congratulations. Polish winter should be at least as harsh as the Swedish one, and I have to confess I don't spend that much time in the workshop, so double congrats :)

I've got a full stainless steel exhaust system and manifold that would suit your car if you are interested ?

Cheers Dan

I thought you sold it with the engine...

It's all about the money ;) I don't know how much it could cost in Poland to make one (probably much cheaper then in UK) and what's good deal for me.

Beside, I'm not sure if it suit my car/engine position (as to the right as possible) but with little modification should be OK.

Is this photo flipped or... I don't know how this fit zx9r ;)

Do you have any photo of it on the car ? (I saw only your old manifold)

TIG welded DIY sprocket adaptor - ready for action ;)

Last purchase:

10GBP - and only one problem - I got no key to ignition barrel... It would be my first barrel breaking in life :)


Genuine MOMO hub (K4524) - I tried it on my column and looks like it fits...
Apart that I already have Raid steering wheel (different PCD)... but for 6,40GBP - I couldn't resist... I'll have excuse to buy snap-off adapter ;)

Next week I'll get another column - adjustable one and OEM Sierra steering wheel...

Nice ingredients going into that roadster soup:cool:

Bob

Take the column to your local auto locksmith and he should be able to read the barrel and make a new key.

TT

Thanks for advice ;) Too late... It's already broken... took me about 1h.
Beside, it could be cheaper to buy new barrel than make a new key...

Yesterday achievements:









It's motivating when you see chassis start to look more and more like a car...

On Friday I picked up my new master cylinder:



As you can see - it's for Fiat - Uno/Panda.
Delphi LM70023 -19,05mm bore, 3x m10x1 outputs. I hope it would be OK for my all-disc setup... (19,05mm bore is suggested by "locostbuiders" to replace standard Sierra 22,22mm master cylinder)
Input fittings are "extra" from my buddy as I plan to use external brake fluid reservoir.

It costed about £12... so one of the cheapest master cylinder on the market ;)

Oh bloody hell yes :)

Yesterday progress (couldn't make more pictures because of flat battery in smartphone).

Today:



My dog's favorite place:

Next update: Saturday (I hope) ;)

Saturday update...






Yes - it's straight (I plan to hide reverse motor and handbrake lever in it)

And now... should I fully weld it, or make rear suspension framework...
Chassis is bolted/welded to build table, so in my opinion it would be better to fully weld it now, then make rear framework, and in the end - weld suspension brackets...

I also made bucket's insert - for electrolysis cleaning (front calipers, maybe upright/hubs):

Another Saturday...

First, I got my Birthday present - mainly form myself, but my "other half" had her contribution in it. Now I'm ready to take care after all this nuts ;-)


I also picked up Fiat Cinquecento seats - bought some time age for... about £10. Naturally seats are too wide, but... I need only runners, which are very easy to modify (only one bar/tube). Universal runners alone cost more than this whole seats...


So, first task was to separate runners form seats...


Few minutes later...

On Thursday I picked upa GRP seats for "client". As my seats will be same but 50mm wider (these are 39cm wide so they are tight), I can plan where I need my runners.






I also made steering support frame...

Finally I couldn't resist to trial fit some components:




Because I didn't want to start something bigger - I prepared tubes and welded pedals...


Next I will fully weld chassis, before I move it forward to weld rear suspension frame...

Today I got my MKIndy inspired laser cut rear uprights:





And... my first SolidWorks finished project - seat mounting plate:

Not sure if you've realised yet, but your chassis has a major design flaw...






Steering wheels on the wrong side :eek: :D

Looking great, especially like the rear upright design. Should be super strong!

Damn, I knew it's something wrong with this angles ;)
I have spare steering column so I can weld second on the other side ;)

Another small step to happiness:

I drill/cut holes for master cylinder...


And fit "custom" CP15 to steering column support:




Of course I have problem with clearance between steering column and TR9, so I will finish it when I get column bearing (maybe friday/saturday).

After long battle, yesterday I picked up column bearing... PFL205 housing + UC205 bearing: