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  #1  
Old 26th March 2011, 03:31 PM
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loony loony is offline
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Default 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
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Lucas

ZX9R BEC Haynes Roadster - build cost so far: 1125
My build thread

"Whatever you can do or dream you can, begin it. Boldness has genius, power, and magic in it." J.W.Goethe
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  #2  
Old 26th March 2011, 06:39 PM
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Did you strip the calipers to paint them, cos I'm stuggling to work out how to pull them apart
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  #3  
Old 27th March 2011, 11:49 AM
flyerncle flyerncle is offline
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If they work ok leave them alone and paint,they are a work of art to strip and repair.
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Cost : Little as possible.
Thanks : To those who by their generosity my build has progressed.
Its a handmade sports car not a flaming kit car !!!


If at first you dont succeed,avoid skydiving...

No parachute require to freefall,only if you want to do it twice.
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Old 27th March 2011, 12:06 PM
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I want to powdercoat them, and the need de-rusting
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  #5  
Old 27th March 2011, 02:58 PM
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I wouldnt bother stripping them just send them to these guys

http://biggred.co.uk/index.php
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  #6  
Old 27th March 2011, 05:37 PM
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loony loony is offline
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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
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Lucas

ZX9R BEC Haynes Roadster - build cost so far: 1125
My build thread

"Whatever you can do or dream you can, begin it. Boldness has genius, power, and magic in it." J.W.Goethe
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  #7  
Old 16th November 2011, 11:55 PM
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loony loony is offline
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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...
__________________
Lucas

ZX9R BEC Haynes Roadster - build cost so far: 1125
My build thread

"Whatever you can do or dream you can, begin it. Boldness has genius, power, and magic in it." J.W.Goethe
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  #8  
Old 18th February 2012, 09:23 AM
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loony loony is offline
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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...
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Lucas

ZX9R BEC Haynes Roadster - build cost so far: 1125
My build thread

"Whatever you can do or dream you can, begin it. Boldness has genius, power, and magic in it." J.W.Goethe
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  #9  
Old 2nd April 2012, 07:42 PM
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loony loony is offline
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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):
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Lucas

ZX9R BEC Haynes Roadster - build cost so far: 1125
My build thread

"Whatever you can do or dream you can, begin it. Boldness has genius, power, and magic in it." J.W.Goethe
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  #10  
Old 2nd April 2012, 07:43 PM
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loony loony is offline
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And parts of sprocket adapter (laser cut 20mm steel donut and turned ZX9R sprocket):
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Lucas

ZX9R BEC Haynes Roadster - build cost so far: 1125
My build thread

"Whatever you can do or dream you can, begin it. Boldness has genius, power, and magic in it." J.W.Goethe
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