Hi Guys
Its been a while since I posted here, I'm now in my second year of Uni and have had to put the project to the side for a while. I'm picking it back up now for a couple of months before I start my year-out placement in industry and I have quite a few questions... sorry!
Firstly, I'm having some issues with my front uprights and the suspension brackets. I've checked and re-checked my jigs and they are correct by my book (494mm center-center lower and 670mm upper?). When I offer it all up there is a gap of about 4-5mm between the upright and bracket on both sides; on the front and rear uprights.
With the U1 & U2 uprights I imagine I could just grind them out and shift them out a bit till they meet the brackets? However the front frame was built by-the-book on the wooden jig so I'm confused why there's a gap... Has anyone else come across this problem? Could I add a 'bulking plate' to make up the gap rather than move the FF2 & FF3 uprights out?
I'm thinking that I'll go with a Zetec engine, has anyone already taken this path? If so did you use the alternative mounting plate as shown in the book and what did you build the engine mounts from?
Headlights - what are people going for, where’s the best place to buy from and what fixing hole size shall I drill (ie is there an industry standard or shall I wait till I have my 'lights?)
Can I buy a fabricated roll-bar unit? I can't find any local companies willing to help me bend up the tube and I don't have the facilities to do it myself, thinking it may just be easier to buy it as a whole.
I'm pretty short
(about 5'7") and it feels like I'm having to move way forward in the car to reach where the pedal box will be, maybe to close for the steering wheel. I'll be putting the seat on runners but has anyone made the pedal box adjustable, or mounted it further back in the car? I'm using a MT75 'box so I've made the adjustments to the TT meaning a smaller footwell - does this mean the pedal box will have to move backwards anyway?
Steering rack and mounts - best place to buy them? what ratio seems to be best?
Are there any pedal rubbers that work well with the book-built pedals?
What brake master cylinder are people using, and what size hole needs drilling in the pedal plate?
Finally, my local shop doesn’t stock bolts with un-threaded shanks for my wishbones, where have you brought yours from?!
That’s it (for now!) - quite a lot in one go I know but any help would be greatly appreciated!
Cheers
Josh