Matt's build thread

[Mking]

Well folks, after many years of dreaming, at least a year of planning and a fair bit of procrastinating I have today come home with a roof rack of steel to start my build. I just need to get a sheet of wood for the build table now and build some supports for it. That should be the job for the next few days. I will try to keep this updated as much for my own motivation as anything else. I can't promise speedy progress as I am the father of 2 young daughters (I'm actually on paternity leave at the moment after my youngest was born 10 days ago). I am amazed I get any garage time but my wife actually told me to get on with the project (I must be getting under her feet).

I lurk on here a lot so have followed many of your stories and I just hope that my ramblings, trials and tribulations entertain some of you as much as you have entertained and inspired me.

Here goes nothing.

Matt

[vmax1974]

Good to see another build getting started I will watch progress with interest

[tkpm]

Good luck with your build

[Dave F]

Good Luck, I too have just started and ultimate respect in getting the Wife to let you out, when my daughters were younger I could't get time to go to the toilet never mind the garage.

[metal matt]

welcome along to the ride. I build my chassis about 6 years ago and had to put it on hold because of young kids and baby's but I v just about finished and hoping to do my IVA retest next Friday.

But good luck with your build.

https://www.flickr.com/photos/124541083@N02/
https://haynes.co.uk/forums/showthread.php?t=13262&page=15

[Mking]

Well it's been a while since I have been on here largely due to:

A) juggling child care, baby care and all the usual household stuff
B) the Mrs declaring that as the baby will be going into the room she uses for sewing she either needs the garage (fat chance) or a workshop of her own which lead to me spending many hours digging in the garden then learning to lay blocks to create an f'ing large flat area which now contains the mother of all sheds ready for conversion into her workshop or Shedquarters as she has named it.

However I have had short blasts in the garage and now have a build table on a frame. The frame is separate and on casters so I can push it around my small garage to make the most of the little room I have. Any suggestions to confirm it's flat? I have laid my metre rule across it and there is precious little if any sag in it.

Now to start marking out and screwing down blocks. I'll try to figure out how to upload pictures with my phone so you can see my minimal progress

[garyt]

glad to hear your back at it :) it doesn't matter how small the steps are , just keep taking them and look at the "shed build" as just another part of the build as we all need to keep the "boss" happy... lol so if she is happy its time well spent..... now crack on :)

[TheArf]

Don't ever forget that your first priority is to keep the kitchen accountant happy, if she is happy your life will be made amazingly easier

Arfon

[Mking]

Work is progressing nicely with the build. I now have the base marked out and blocks in place to help position the metal. Getting it all marked out and square was a P.I.T.A but I think I am there or there abouts now although there may be some fettling needed once the tubes are cut I don't doubt. I'm amazed by the different measurements you can get using 2 or 3 different measuring tools even thought they are supposedly the same. As for tools that are meant to be square well I'm amazed by the differences.

Anyway I'm now looking forward to cutting the first bits of metal and seeing the start of my chassis for the first time.

[dean211277]

Good luck with your build.

We are about at the same stage as I have just finished marking out my build board, as you say takes a bit of time measuring and double checking but worth it in the end.
I bought a roofers square which really helped us build the table and I've used it in marking out to, I have checked it and it seems quite accurate!

Do you know what donor car you will be using?

[Mking]

Yes, I bought a roofers square too as well as a 1m steel rule that made the whole process much easier. I plan to use an Mx5 donor as long as I can find one that is a reasonable price but need to do much of the building first as I don't have room to store parts and build at the same time

[Dave F]

Yes, I bought a roofers square too as well as a 1m steel rule that made the whole process much easier. I plan to use an Mx5 donor as long as I can find one that is a reasonable price but need to do much of the building first as I don't have room to store parts and build at the same time

I put a WANTED add on gum tree, I was offered a complete car for £200, rotten as sin but complete and running but was 100 miles away. I was also offered a part stripped car for £150 that had all the parts I needed. He then delivered it for £50 so for £200 I had a donor with all the parts needed on my drive, as it was part stripped saved me a certain amount of stripping aswell

[Mking]

I put a WANTED add on gum tree, I was offered a complete car for £200, rotten as sin but complete and running but was 100 miles away. I was also offered a part stripped car for £150 that had all the parts I needed. He then delivered it for £50 so for £200 I had a donor with all the parts needed on my drive, as it was part stripped saved me a certain amount of stripping aswell

That seems like a good move. I will try that when the time comes. I had hoped to use a BMW 3 series but I was scared off by the modifications I would have to work out myself.

[Mking]

I put a WANTED add on gum tree, I was offered a complete car for £200, rotten as sin but complete and running but was 100 miles away. I was also offered a part stripped car for £150 that had all the parts I needed. He then delivered it for £50 so for £200 I had a donor with all the parts needed on my drive, as it was part stripped saved me a certain amount of stripping aswell

That seems like a good move. I will try that when the time comes. I had hoped to use a BMW 3 series but I was scared off by the modifications I would have to work out myself.

[RichardH]

mx5 come up all the time on gumtree in edinburgh but you need to be quick the drift guys want them, i missed several before i got one. but take your time and get a mk2 1.8 with lsd if possible

[RichardH]

have you got some welders magnets? they hold the parts at right angles to oet you weld, also very good for mocking the car up before you tack weld.i had the whole rear section held with magnets before i welded it together.

[Mking]

have you got some welders magnets? they hold the parts at right angles to oet you weld, also very good for mocking the car up before you tack weld.i had the whole rear section held with magnets before i welded it together.

Yes. I bought some in Lidl recently when they came up on special offer

[flyerncle]

Measure twice,and then again and cut once.
I made a fully welded chassis 30mm to long as I drew another line for the front frame .:eek:

[Mking]

Well today has been a big day for the build (not as big as those who have passed their IVA but bare with me). I have cut the first bits of metal and positioned them on the build table. I'm having to do it all with a hack saw so as to keep noise to a minimum (integral garage) and to avoid the cost of a power saw so I now feel like I have done a mini gym session but hey at least it will keep me in shape.

[RichardH]

i have a chop saw you are welcome to borrow, its noisy though

[Mking]

i have a chop saw you are welcome to borrow, its noisy though

That's really good of you. The only chance I get to work on it is when the kids are in bed so quiet is important at the moment but I might come back to you if I lose patience with the enforced gym sessions.

[Mking]

Good luck with your build.

We are about at the same stage as I have just finished marking out my build board, as you say takes a bit of time measuring and double checking but worth it in the end.
I bought a roofers square which really helped us build the table and I've used it in marking out to, I have checked it and it seems quite accurate!

Do you know what donor car you will be using?

Yes, my roofers square was invaluable. I didn't realise how much I needed one until I bought one. I am going to use an Mx5 donor, hopefully 1.8. I am doing it slightly our of sinc as I have limited space so building as much of the car as I can then will buy the donor and hopefully pretty much transplant bits from it into the Roadster. How is your build going?

[Mking]

Well folks it has been a while since I have posted on here but there has been progress, if slow. Since the last update I have had to have stints away from the project to finish off the wifes sewing shed, build a new chicken enclosure for the garden, do endless jobs around the house and go away with work. However, I have managed to steal a few precious hours in the garage here and there and tonight have finished cutting all the bottom chassis rails. The only ones I made a total ar5e of were br1 and 2 whose angles were way off and the gaps to the other rails were far bigger than even enthusiastic welding would fill. I found measuring the angles quite tough given the size of the tube. I ended up re doing them and just measuring the metal in situ. It seems to have worked well. On measuring the chassis now it all seems parallel and my very old and good quality set square shows the angles are all nice and square too. Now just to cut some wood to fix it all to the table then I can break out the welder.

On the subject of the table I found it had sagged slightly. Only a few mm's but enough to concern me. I have fitted extra wood so hopefully it is now totally rigid.

[Mking]

Crikey, I can't believe it has been August since I updated this. Those who are on the Facebook page will have seen I have made progress on the chassis. It's not been quick but not bad given its been fitted around childcare/work etc. I am now up to the rear suspension and rear end. I have ordered the 20mm steel today so can crack on once it arrives.

I have been trying to decide whether to make suspension brackets but after realising this seems to be a ball ache and getting them accurate adds difficulty, I am going to buy them instead. The wishbones are also causing me stress but I hope once I make the jigs and cut the pieces it will all come together.

I have just realised the angled tubes on my front frame are twisted slightly. I am going to cut the tubes out, fettle them, and weld them back in to save issues with the suspension mounts.

[SteveH1]

Hi Matt
The wishbones are not a big deal to make really just time consuming really
Plus the top one for the rear is too short not sure what length it should be though