Another build thread

[skov]

I thought I'd better start a build diary, and this seems a good a place as any, so here we go with a little introduction.

It all began on new years day, I was idly browsing Amazon when I happened upon 'the book'.
I suspect that might turn out to be the most expensive impulse purchase I've ever made!
It took most of January to clear/organise the garage, and I'm still not quite there... Yes it was that bad! Still a fair bit of junk to clear out.

The last few days have been spent knocking up a rather rickety build table.
I just need to add a bit more support to the legs and mark out the top and I should be ready to rock!
Sadly I'm not as blessed in square footage as most people here seem to be, so this is where it's all going to have to happen:

https://lh4.googleusercontent.com/_KhLoFzSFH8k/TU530XwwFYI/AAAAAAAAGuc/TYh22GViLcc/s640/workshop.jpg

The keen eyed might spot one of Handy Andy's flat pack kits on the desk at the back.
I picked it up second hand from this very forum.
The guy selling it never got around to starting but had still managed to 'misplace' some of the bits.
Lucky for me Handy Andy was kind enough to replace them free of charge :D

Donor wise, I'm 99% sure I'm going to go MX5.
My current toy car is a Mk1 import, and I'm still trying to decide whether to use it as the donor, or look out for a crashed one.
It's in reasonable nick so it seems a shame to break it, but on the other hand I know it's been looked after and all works!
Either way it's going to have to go to make space for / fund the roadster build:
https://lh5.googleusercontent.com/_KhLoFzSFH8k/TU531FwGJmI/AAAAAAAAGuk/qLGLhrX_2Qk/s640/possible_donor.jpg

I'm hoping to make a start welding the chassis in the next couple of days, so hopefully I'll have some real progress to report soon!

-----------
EDIT: Shortly after I started my build Saturn announced the development of their MX5 roadster.
Luckily I hadn't got very far with mine, so rather than reinvent the wheel (and c0ck it up!), I thought it'd be easier/safer to just copy their design :)
-----------

[K4KEV]

Welcome to the forum Skov....you would not be alone in the scary space dept, I have a double garage but it seems like a single with all the junk..... and there are lots on here that are in the same boat as you....is that an old suz TS I see there, vintage now....I also see you are a aeromodeller if you fancy any large aircraft plans drop me a line I have loads, not that you will any time to build aircraft once you get started with this. Any Q's just ask on here and you will get a quick responce, a lot on here are now been there, done it, got the t shirt brigade....keep us up to date dude;)

[twinturbo]

Good luck,

I have a 1 1/2 size garage. It's a good size.

But full of stuff for cars. I think there's 6 engines in there, 6 gearboxes. Countless ancilliaries, bits, bobs and junk. Only just enough space to get to the roadster.

TT

[skov]

Welcome to the forum Skov....you would not be alone in the scary space dept, I have a double garage but it seems like a single with all the junk..... and there are lots on here that are in the same boat as you....is that an old suz TS I see there, vintage now....I also see you are a aeromodeller if you fancy any large aircraft plans drop me a line I have loads, not that you will any time to build aircraft once you get started with this. Any Q's just ask on here and you will get a quick responce, a lot on here are now been there, done it, got the t shirt brigade....keep us up to date dude;)

I'm ok for aircraft plans, but thanks for the offer - can't see me doing any aeromodelling for a little while now!
The top of the garage and my attic are bulging with airframes waiting to be repaired as it is :rolleyes:
The bikes are my son's old Yam TY80, which is getting pretty vintage now (late 70's I think), and my 2002 Gasgas 280 pro.
Talk about too many hobbies and not enough time. or space for that matter!

[shh120m]

Good luck,

I have a 1 1/2 size garage. It's a good size.

But full of stuff for cars. I think there's 6 engines in there, 6 gearboxes. Countless ancilliaries, bits, bobs and junk. Only just enough space to get to the roadster.

TT

You wouldnt happen to have a spare T9 in said garage would you?;)

[CaptainCrash1971]

Hi Skov, welcome to the forum. If you take a look at my build blog (address in signature) you'll see my garage is of a similar size, so I'm sure you'll manage. I'm planning to get my car up to rolling chassis stage asap so I can wheel it out onto the drive to do work on it once the weather gets better.
Just enjoy it mate, and keep us updated.

[twinturbo]

You wouldnt happen to have a spare T9 in said garage would you?;)

I have 2 , but they are V6 and they are alllllll mine!

TT

[skov]

First few bits tacked into place :D

https://lh4.googleusercontent.com/_KhLoFzSFH8k/TU8QNsRCO6I/AAAAAAAAGvM/s-az4Py7L-g/s640/S5032104.JPG

[Bonzo]

Nice to see that you have made a start skov :)

I know how great it feels to get those first few tubes on the board & tacked up :cool:

The MX5 looks far too good to break, pehaps you'll be lucky enough to find a dammaged one in a breakers .... That said, needs must & all that :D :D

[skov]

Nice to see that you have made a start skov :)

I know how great it feels to get those first few tubes on the board & tacked up :cool:

The MX5 looks far too good to break, pehaps you'll be lucky enough to find a dammaged one in a breakers .... That said, needs must & all that

Yep, it certainly did feel good! Can't wait to get back in the garage now. I could have stayed out there all night, but I need to be careful if I want my marriage to outlive the build :rolleyes:

I've got another 6 months tax/insurance left on the Maz, so I won't be selling or breaking it before then. In the meantime I'll keep an eye out for a cheap one.
To be fair mine is showing the first signs of sill rot, so it's days are numbered anyway. At least that's my excuse if I do break it :D

[fabbyglass]

Bugger the car that TY80 brings back cool memories as my first bike was a TY50 in the same colours......:cool:

[skov]

A little more progress today - managed to finish tacking down the BR's :)

[skov]

Collected an MX5 diff, driveshafts, and rear uprights today:

https://lh6.googleusercontent.com/_KhLoFzSFH8k/TVMILvhYsII/AAAAAAAAGv0/bOs7b6H5A8k/s640/diff.jpg

Won them for a whopping 99p on ebay!

[JakeH]

looking good! iv been clearing out for the last 3 years and im still not there, i think someone just keeps filling the space i make! :rolleyes:

bargain on the bits!

[leroybrown911]

TY80, class brings back memories! Good luck with the build

[skov]

Nice to see the TY is bringing back a lot of fond memories!
All it's doing is p!ssing me off at the moment - the brake pedal gouges a hole out of my leg every time I walk past it :mad:
Might have to invest in some shin pads!

Made a little more progress today. Managed to get U3 to U6 down.
I was struggling to get them aligned, until I discovered we had some welding magnets at work. Had them done in a jiffy with those :D

https://lh4.googleusercontent.com/_KhLoFzSFH8k/TVRLyyewsSI/AAAAAAAAGwM/YJMPYbSxr-0/s640/chassis_uprights_done.JPG

May be a bit premature, but I couldn't resist doing to air steering wheel / brum brum test :cool:

[Aussie_Haynes_MX5]

Nice to see the TY is bringing back a lot of fond memories!
All it's doing is p!ssing me off at the moment - the brake pedal gouges a hole out of my leg every time I walk past it :mad:
Might have to invest in some shin pads!

Made a little more progress today. Managed to get U3 to U6 down.
I was struggling to get them aligned, until I discovered we had some welding magnets at work. Had them done in a jiffy with those :D

https://lh4.googleusercontent.com/_KhLoFzSFH8k/TVRLyyewsSI/AAAAAAAAGwM/YJMPYbSxr-0/s640/chassis_uprights_done.JPG

May be a bit premature, but I couldn't resist doing to air steering wheel / brum brum test :cool:

Premature? I had my build board marked up and sat on it where the seat was and did the brum brum and air wheel.

[spud69]

Premature? I had my build board marked up and sat on it where the seat was and did the brum brum and air wheel.

Did you have a Tinney in your hand to.....;) Like this one of mine:

[fabbyglass]

Blimey 99p that's a bargain!!! Are the MX5 diffs all the same set up? what horsepower can they safely take?
If the TY is in the way I will look after it for you.......:D

[skov]

Blimey 99p that's a bargain!!! Are the MX5 diffs all the same set up? what horsepower can they safely take?
If the TY is in the way I will look after it for you.......:D

I was quite surprised about the 99p, I was expecting to pay a fair bit more than that, but no one else bidded. I don't think the seller was too pleased... :rolleyes:

As far as I know, all the Mk1 differentials are interchangeable (the Mk2 and 3's are completely different, and I don't know anything about them).
The UK models tend to have open diffs, whereas the Jap imports tend to have LSDs (viscous on the early 1.6, and torsen on the 1.8).
This one is off a 1.6, and is probably an open diff. Ideally I want to use the 1.8 torsen, but this will do for now (I believe I have a torsen in my MX5 - it certainly goes sideways very nicely :D )
Mk1 MX5 kicks out 120-130bhp as standard. Many people have turbo'd them to 200bhp+ without any diff trouble (as far as I'm aware!) No idea what the maximum they could handle is.

I don't think my son would be too pleased if I let you 'look after' his TY!!!

[Deanno]

Bugger the car that TY80 brings back cool memories as my first bike was a TY50 in the same colours......:cool:

I've got the TS100 it was my first my Dad Turned it into a grass track bike for me. still got it 14 years later :D

[skov]

Met Headshot off the forum today and purchased his suspension bolt set and steering column.

Back in the garage I got TR1,2,8, and 9 tacked down, and got the all important beer shot for Spud69 :D

https://lh6.googleusercontent.com/_KhLoFzSFH8k/TVWtQ3nVQeI/AAAAAAAAGww/JEy7ClfcPu4/s640/the_all_important_beer_shot.JPG

[HandyAndy]

Wow, looking great skov, that donor looks really smart, :eek:
Hope you are enjoying your build,
Great photo sat in the chassis :D

Look forward to seeing more of your progress.

Cheers
Andy

[skov]

Wow, looking great skov, that donor looks really smart, :eek:
Hope you are enjoying your build,
Great photo sat in the chassis :D

Look forward to seeing more of your progress.

Cheers
Andy

Thanks Andy :D
I have to admit, a few people have told me I'd be nuts to break my nice shiny 5! We'll see...
I'll be sure to post some more pics when I've actually made some progress.
I've been struggling a bit with the SB1's, but I think I know what I'm doing now.
Your kit's fitting together very well by the way. Only had to trim a couple of bits :cool:

[HandyAndy]

:cool: I must agree, your five does in great condition, but hey, you'll have a great Roadster at the end of the build too ;)

Glad to hear the kit is going together well, but don't forget that if any of the parts give you a problem, let me know and I'll replace the offending part free of charge, I stand by the guarantee I offer on all my kits, :)

Cheers
Andy
(sent this off the new phone, so hope it works):o

[spud69]

your five does in great condition

:D Think your phone is working fine just your fingers are not.....:p

[HandyAndy]

:D Think your phone is working fine just your fingers are not.....:p
somebody phoned me whilst I was typing that post, I wonder who that could,ve been eh Spud?? :D

And I'd missed a word out, oops
:o ...all fingers and too many thumbs here

Cheers
Andy

[skov]

Managed to grab some garage time over the last couple of nights, so here's another boring chassis photo :p

https://lh4.googleusercontent.com/_KhLoFzSFH8k/TV2PskNkT9I/AAAAAAAAGzc/ZJn93G5sZ9E/s640/seat_back_and_top_rails.JPG

Starting to take shape now :cool:

Spud/Handy - going to need your MX5 tranny tunnel / rear end dimensions soon!

[HandyAndy]

:cool: Nice work there Skov,

Yup...it looks like you are ready for the tranny tunnel info :) .....I,m seeing Spud in the morning, I,ll chat to him about getting the info to you, Spuds done some great work on the MX5 chassis, its looking great.

Don,t put the "RS" or SB4,s parts in place just yet ;)

cheers
andy

[skov]

Had a couple of hours to spare last night, so went out to the garage.
Managed to put two blobs of weld down before my little disposable cylinder ran out :mad:
Popped to my local welding supplier today and treated myself to one of these:

https://lh6.googleusercontent.com/_KhLoFzSFH8k/TWbPqRGeTAI/AAAAAAAAG0I/DcTFb90X2DM/s512/albee_argon_CO2.JPG

Shouldn't need to worry about running out of gas any time soon now!
Seems to produce far nicer welds too :cool:

[will_08]

Cool whats in it? and whats the quantity?

I ended up buying a CO2 cylinder

[skov]

Cool whats in it? and whats the quantity?

I ended up buying a CO2 cylinder

It's one of these:

http://www.albeegascylinders.com/index.html

11 litres of Argon CO2 (15%).

[will_08]

Cheers Skov, i trawled the net everywhere to see if it was possible to get argon mix without a contract, then like i said ended up buying CO2.

But i think ill give my local supplier a phone about one of these

Cheers Will

[skov]

Not much to report. Just been doing a few little bits and bobs while I wait for some parts to arrive (and for Saturn to release their MX5 plans!)

https://lh5.googleusercontent.com/_KhLoFzSFH8k/TXFXxZf-wPI/AAAAAAAAG1Y/YdfSC90i5us/s640/in_progress_4th_march_2011.JPG

Whipped one of the seats out of my mx5 tonight to see if it would fit.
Sadly it looks like they're going to be a bit too wide :mad:
I was hoping I wouldn't have to splash out on new seats until after I got it on the road...

https://lh6.googleusercontent.com/_KhLoFzSFH8k/TXFXxZqHRjI/AAAAAAAAG1c/euF88_WTP2Y/s512/mx5_seat.JPG

https://lh6.googleusercontent.com/_KhLoFzSFH8k/TXFXuNcYYqI/AAAAAAAAG1Q/OB6XYHlyb0E/s512/mx5_seat_too_wide.JPG

[Spikehaus]

Your seat look no wider than my own, I was not planning on adjusting them to much, so a little wear and tear, so be it.

Just seen your build, not had the chance to wish you well, looks like you will be motivated to keep it moving

[skov]

Your seat look no wider than my own, I was not planning on adjusting them to much, so a little wear and tear, so be it.

Just seen your build, not had the chance to wish you well, looks like you will be motivated to keep it moving

Thanks for the well wishing!
I tacked one side of the tranny tunnel in place yesterday and checked the seat again - it just sat on top of the rails, it's never going to fit between them!
To be fair, they weigh a ton anyway, so it's a good excuse to buy some nice light ones :cool:

[alga]

Sure they fit, you just need to use some persuasion:
http://www.cheapsportscar.net/diary.php?UID=202
http://www.cheapsportscar.net/diary.php?UID=206
http://www.cheapsportscar.net/diary.php?UID=211

[skov]

Fair point Alga, I suppose anything is possible and all that!

The build's still ticking away slowly.
No pics today I'm afraid, but I did the mythical CP24's and the steering rack support last night.
I've also been constructing the headlight brackets recently.

It's been like xmas at work this week, the postman's brought me some plates/brackets, a Micra Radiator, a pair of alloy steering rack mounts, and some rear wings (won't be needing them for a while!) :cool:

[skov]

Just finished tacking the tranny tunnel.
Happy to have that finished, it had been bugging me having to leave it half done.
Many thanks for the dimensions if you're watching Handy - Looking forward to the next installment :D

https://lh6.googleusercontent.com/_KhLoFzSFH8k/TYEqWIYMGkI/AAAAAAAAG2Q/Ry1Vy2AMAQQ/s640/tranny_tunnel_top.JPG

You may have noticed the tranny tunnel flares out at the rear.
This is because the input to the MX5 diff is offset slightly, so it needs to come out to avoid interference.
The rest of the tunnel is 'book spec. Have to say Saturn seem to be doing a great job fitting the MX5 gear, whilst keeping the chassis close to the original design.

[twinturbo]

I tried for ages to find a decent seat design, but the gap is very narrow. I went for the KPD ones eventualy.

TT

[skov]

I tried for ages to find a decent seat design, but the gap is very narrow. I went for the KPD ones eventualy.

TT

Funily enough I was looking at the KPD website at lunchtime and trying to decide whether to go for their fibreglass or '7 style' seats.
Can't make my mind up :rolleyes:

[twinturbo]

I did use the KPD runners, you will need 4 fine pitch M8 bolts per side too ( sierra seat mount bolts are ideal )

http://www.haynes.co.uk/forums/showpost.php?p=44742&postcount=19

Mounted on 25mm box. for some reason one of my rear tubes was not quite in the right place so I added a second (helps take the weight too ;) )

TT

[skov]

I did use the KPD runners, you will need 4 fine pitch M8 bolts per side too ( sierra seat mount bolts are ideal )

http://www.haynes.co.uk/forums/showpost.php?p=44742&postcount=19

Mounted on 25mm box. for some reason one of my rear tubes was not quite in the right place so I added a second (helps take the weight too ;) )

TT

Any chance you could measure the position of your tubes for me please?
I want to get the supports in, but don't want to have to buy the seats/runner just yet!

[twinturbo]

Will have a look for you later if I remember.

TT

[skov]

I picked up my donor today, a rather tatty 1.6l Eunos Roadster.

I got about three miles down the road before it spat the pulley off the end of it's crankshaft, resulting in no power steering, water pump, or alternator :rolleyes:
The nice man at the RAC got it the rest of the way home for me though :cool:

https://lh5.googleusercontent.com/_KhLoFzSFH8k/TYpPNls0DuI/AAAAAAAAG2w/JdvKj6IHpFI/donor.jpg

[james3004]

Looks like your getting on well john, at this rate you'll catch me up :)

Out of interest how much was the gas and did you get it from starmaker? I have got a BOC contract but it's pretty damn expensive especially if your not using it much

[CTWV50]

I'll be watching this thread closely! Interested in the cost of the gas too!

[skov]

My gas wasn't cheap...
Think it was about £180 to buy the bottle outright (which includes a built in regulator).
Refills/exchanges are then around £38 a pop.

You need to start a thread soon CTWV50, it'd be good to compare notes :)

Haven't done anything on the build for the last couple of weeks, been busy with far less interesting things.
Made a start stripping the donor at the weekend though, and already sold a couple of hundred quids worth of stuff on ebay and mx5nutz. I've got high hopes of breaking even on it!

[spud69]

I'll be watching this thread closely! Interested in the cost of the gas too!

Try Energas if you have a local branch i have found them to be the best. There is a small monthly rental but you dont have to pay upfront for the bottle, just for refills at a decent price

Andrew

[CTWV50]

Just phoned a local supplier an 11 litre bottle is £139.25, Quick release fitting and reg £9.99, refills £36.75. How much gas am I likely to use, no experience at all of this sort of thing.

[CTWV50]

A local company are doing me a boc bottle for £73 a year rental and £33 for refills it's 1 meter tall bottle. Seems like a reasonable deal. Erm were did you get those little plastic blocks from for the jig? And what are they? Can't find the little buggers anywhere!

[K4KEV]

the little plastic blocks tend to be the ones that hold most kitchen cabinets together so hardware section of b and q or screwfix/toolstation etc

[CTWV50]

Ahh thanks

[skov]

Erm were did you get those little plastic blocks from for the jig? And what are they? Can't find the little buggers anywhere!

I got a bag of 100 of those little blocks off ebay, which is more than enough! Try searching for 'modesty blocks'.

[skov]

Just got a cheque for £68.33 from the DVLA for road tax refund on my donor :cool:
Makes a change them giving me money!

[skov]

After a bit of a delay I finally got started on my rear end yesterday and got the diff cage tacked into place:

https://lh4.googleusercontent.com/_KhLoFzSFH8k/Tbh7ugsh5WI/AAAAAAAAHB8/mA6cECBKMEg/s640/diff_cage.JPG


This evening I borrowed my mate's crane and whipped the engine out of the donor:

https://lh6.googleusercontent.com/_KhLoFzSFH8k/Tbh8ZzSKkVI/AAAAAAAAHCg/460iLNIsgx4/s640/engine_out.JPG

She's looking very sorry for herself now. Poor thing!
https://lh5.googleusercontent.com/_KhLoFzSFH8k/Tbh8bjU6MqI/AAAAAAAAHCk/uqABpxI7tsw/s640/naked_inside.JPG
https://lh6.googleusercontent.com/_KhLoFzSFH8k/Tbh70PRtiwI/AAAAAAAAHCE/IFgAXMtNt8M/s640/bare_bay2.JPG

[twinturbo]

Always good to have the engine out of the donot :)

TT

[CTWV50]

Oooo progress, I'm so jealous. Have you sold the entire interior?

[skov]

Oooo progress, I'm so jealous. Have you sold the entire interior?

Not all of it yet, but a fair bit has gone.
Interior wise I've sold the dash, radio surround, heater controls, hazard switch, seat belt stalks, drivers seat belt, seats, runners, one door pull/handle, style bar, chrome vent rings, cluster cowl, floor console, gear knob, ashtray, window switches, sill plates, and floor mats. Still got all the carpets, door cards, and some bits of plastic trim. I'm sure they'll go eventually though!
None of it went for much, but it soon mounts up.
So far I've got about £410 back from the donor after postage and ebay/paypal fees. Another £90 and I'll break even :D

[CTWV50]

Right I'll be listing mine this weekend!:) Can you link me your sale thread so i can see the format? Thanks.

[skov]

Right I'll be listing mine this weekend!:) Can you link me your sale thread so i can see the format? Thanks.

Noooo, I don't need any more competition :p

I stuck most things on a 30-day buy-it-now listing, with the price set slightly cheaper than similar items.
I kept the listings nice and simple, as it's a pain in the ar5e entering them all.
Here's one of mine (http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=180659036759&ssPageName=STRK:MESELX:IT)
I had things flying out of the door every day for the first couple of weeks, but it's slowed down now I only have the less sought after stuff left.

[skov]

Well I didn't make it to Stoneleigh, but I did get a fair bit of garage time over the long weekend.
The donor's now stripped of everything I need and anything worth selling and is ready to be scrapped.
Also made some good progress on the rear end :)

https://lh6.googleusercontent.com/_KhLoFzSFH8k/Tb8Wu-Mz-4I/AAAAAAAAHHA/6pUzY1sBHh0/s640/donor_stripped.JPG

https://lh5.googleusercontent.com/_KhLoFzSFH8k/Tb8WwpKP4UI/AAAAAAAAHHE/U2ostURtMQM/s640/rear_progress_02052011.JPG

[james3004]

looking good john:)

[skov]

Thanks James :cool:
Not looking as good as yours, can't wait to get mine off the table and on it's wheels too. Got a little bit to do first though...

I pretty much finished the rear end this weekend. Just need to add the wishbone mounts and tank support plates, then I should be ready to fully weld the chassis. I'm not sure whether I'm looking forward to, or dreading that much welding!

Got rid of the donor chassis today, which I'm very happy about, not nearly as happy as my neighbours are though :rolleyes:

[CTWV50]

can't wait to get mine off the table and on it's wheels too. Got a little bit to do first though...

Same here but I have a little bit more than you to do!:o

[skov]

Just a tad - I'm sure you could catch up soon enough it you put your mind to it though!
Good to see you over on oddunit.com (http://www.oddunit.com) by the way, small world indeed!

I just got a new toy, which might slow my build down a bit.
I had sworn not to ride bikes on the road again, but a mate gave me this for free last weekend, and I might just have to get it roadworthy and potter about on it for the summer.
Not exactly the fastest bike in the world, so hopefully won't get me into too much trouble!

https://lh3.googleusercontent.com/_KhLoFzSFH8k/Tc56kJboWSI/AAAAAAAAHJ8/__8Dv9ijBlc/s640/S5032456.JPG

[skov]

Well, I've not had the most successful bank holiday weekend.
First I ran out of welding gas, then I managed to grind through my grinders power lead.. doh!

Other than that, I'm well on my way to having a fully welded chassis, and I've made a start ripping all the cr&p out of the wiring loom that I don't need :cool:

https://lh5.googleusercontent.com/-Vk1KzvrqxnU/TeQQ2SrTIDI/AAAAAAAAHQU/we3x-pRHgeU/s640/mx5_loom.JPG

I put the chassis on it's side to weld the bottom of it. Clearance above it couldn't have been much tighter if I'd tried:

https://lh5.googleusercontent.com/-LcjU57-jHfA/TeQQtBAEfHI/AAAAAAAAHQE/euAX5eZCZVc/s640/chassis_sideways.JPG

[skov]

A new steering wheel arrived in the post today. It's an original MX5 one, which is nicely padded and should pass the IVA:

https://lh5.googleusercontent.com/-zbFMkINZxZU/TeS652L9lmI/AAAAAAAAHQ0/_u6LNvg-dmc/s512/mx5_oem_wheel.jpg

I got it to replace this aftermarket one which came with the donor. This one had no chance of passing IVA, but also has such a silly amount of dish that I couldn't reach the indicator stalk without taking my hand off the wheel :rolleyes:

https://lh3.googleusercontent.com/-kSDB8lR7bt0/TeS66Poy-KI/AAAAAAAAHQ4/dNEZMjLTZU0/s512/mx5_donor_wheel.jpg

[CTWV50]

I must of put about 60 hrs into the mx5 loom separating engine from lights, nearly there now, and I'm enjoying it perversely! Can't believe how much stuff goes back to the ECU! Did you have an immobiliser on your car? Are you going to keep it?

I keep thinking! I'll sell that, then I think, no, what about the IVA!!:o

[skov]

My donor had an immobiliser and an alarm/immobiliser fitted, had to pick both of the buggers out of the loom! I flung them in bin...
I've spent a fair few hours on the loom too, and still got a lot to do.
I'm currently thinking I might strip it right down to the bare essentials needed to get the engine to run, then make my own loom for lighting and instruments.

[CTWV50]

Yes I've eliminated the immobilser for the time being, just so when I fit it and the engine doesn't start I don't have to wonder if it's the immobilser. I may refit it if after the IVA if it reduces the cost of insurance. As for making a light loom I think it would be more hassle and expense. I separated the engine from the lights just so if/when I go aftermarket ecu I don't end up pulling the whole loom out to do so, Also I don't want any wires running past the hot side of the engine so it's clear for the turbo install at some point in the future.:)

[skov]

More goodies arrived in the post today, courtesy of tigmatt :D

https://lh4.googleusercontent.com/-rOD3Jxa_kJ4/TeeJcER8QXI/AAAAAAAAHRY/Luda-mXqjYs/roll_bar.jpg

https://lh5.googleusercontent.com/-ZqEbmpGH_uM/TeeJbaoc7JI/AAAAAAAAHRU/DlFPGApaS9Y/s800/nosecone_scuttle.jpg

[skov]

This cluster arrived from ebay yesterday afternoon:

https://lh3.googleusercontent.com/-z9aI9WzD--8/TfOkeHEL9WI/AAAAAAAAHTM/BThHCX30jzo/mini_cluster.JPG

It's from a 'new' Mini, and I thought it looked rather nice and would suit the Roadster. Plus it was cheap at £16 :D

The only slight issue is that it's controlled entirely from the CAN Bus in the Mini.
I like a challenge, so...

First thing I did was take the back off and see if I could figure out the pinout for the connector.
There's only 7 pins on it, and I quickly found the pins for GND, Battery, CAN-H, CAN-L, and the backlighting. That leaves two pins I don't know the funtion of, but I don't think I need them.

I cracked open my CAN interface and started sending random messages to see if I could get anything out of it. That was less than sucessful, so I did some googling.
Lucky for me some guy had recorded the CAN bus on his Mini, had a go at analysing it, and stuck his findings on the web. He had only identified a couple of the messages, but that was just the kick-start I needed, so I stuck my reverse engineering cap on and got to work.

A few hours later and I can now control the following functions from my laptop:

* Speed
* RPM
* All the tell-tale / warning lights
* Backlight intensity
* Position of the red-line

The only thing I can't do yet is get anything sensible displayed on the two little LCDs, but I'm working on that.

The next stage of this sub-project as it were is to design a box that will sit in the car, monitor various signals, and generate the CAN messages for the cluster. That'll give me something to do in my lunchtimes at work :D

Here's a screen shot of the program I knocked up to talk to the cluster:

https://lh4.googleusercontent.com/-IsAsZyU5pNE/TfPYfBx8bsI/AAAAAAAAHTY/rWh7KPyLuW0/s720/mini_cluster_interface.jpg

And there's a little vid of it in action here (http://youtu.be/vvd_c9bAbd0) (very poor quality I'm afraid).

[ginger nutter]

that is goin to look great I wouldnt have a clue how to go about working all that out, good work

[MarkB]

Clever stuff, I'm always amazed how folk can make head or tail of all that lecy wizardry...clocks look smart too:)

[twinturbo]

So what do you use for the CAN interface?

TT

[skov]

Thanks guys. To be honest my job often involves playing around with CAN busses, so this is bread and butter stuff for me :)

TT - this (http://www.can232.com/) is the CAN interface I'm using.

[CTWV50]

Genius!:cool:

[CTWV50]

Thought about changing my clocks too but sort of stopped when I realised you needed warning about break fluid, engine temp, oil pressure, and the ecu has a speed sensor which is in the clocks from the manual speedo I think. How do you get round all that!:confused:

[MarkB]

Thanks guys. To be honest my job often involves playing around with CAN busses, so this is bread and butter stuff for me :)

TT - this (http://www.can232.com/) is the CAN interface I'm using.

Please excuse my ignorance but what are "can busses" I immediately thought of double decker buses and "blakey"... :o

[Andy_B]

its a doofer that allows devices to comunicate to each other without a "host" computer....if i remember back to my college Mechatronics course !!

[skov]

Thought about changing my clocks too but sort of stopped when I realised you needed warning about break fluid, engine temp, oil pressure, and the ecu has a speed sensor which is in the clocks from the manual speedo I think. How do you get round all that!:confused:

Yeah, the Mk1 speedo is driven by a cable, and the speed pulse for the ECU is generated in the clocks.
Not a huge problem though as you can replace the cable with a Mk2 vehicle speed sensor.
The fluid level sensor is just a switch in parrallel with the handbrake switch, so that's easy enough.
I' not sure what you could do about oil pressure and engine temp. If you're lucky the levels might be compatible with aftermarket gauges. I plan to monitor them and light up one of the lamps in my cluster if they go out of normal operating range (or hopefully display their values on the cluster LCD if I can work out how to talk to it).

[CTWV50]

Modern cars use a network interface to talk to different parts of the cars computer controlled system. I'm sure skov has a better explanation!

edit:

So if you can fiddle the clocks you maybe able to get the warnings from it, like for handbrake, fluid, oil, temp etc?

[twinturbo]

CAN "Controler Area Network"

Is a way to simplify wiring.

If you think of it in it's most most basic terms, imagine the sierra wiring with tones of wires all over the place goign to lights, door locks, clox, engine management, stereo, etc..

Now..

replace that with 3 wires. Data send, Data receive, +12V .. Add a localized ground and all your big wire bundles disapear.

You have lots of intelligent localized controllers that listen for signals relating to them. They then process the signal and do what they are required with much shorter local wiring.

TT

[skov]

Yep what he said :cool:

I'd been struggling to think of how to explain it simply!

[skov]

I replaced the liner in my welder this evening after it got completely blocked last week. What a difference it's made!
It had always had a slightly erratic wire feed, but now it's silky smooth and making it loads easier to get decent welds :cool:
I'm just kicking myself for not doing it 6 months ago!

[CTWV50]

Just ordered a teflon one off the bay, think mines ok for now but when I change the weld wire real I'll fit the new one see what happens. How are the clocks coimng along, could be interested in running these myself with your help.:)

[skov]

It's well worth changing. Only problem is I need to figure out all my wire speed settings again as it feeds the wire quicker for a given number on the dial now :rolleyes:

I think I read somewhere that teflon liners for for aluminium wire, and will wear out very quickly with steel. I could of imagined that though.

Haven't got too much further with the clocks yet. I've figured out how to control everything I need to on the cluster (speed, rpm, and all the warning lights), but I can only make the two LCDs display random cr&p at the moment.
I've made a start sketching out a design for the cluster interface box, but I'm a bit undecided on how complicated to make it, and whether to incorporate some other features.
If I can get it all working nicely I'm sure I could be convinced to make two of them ;)

[CTWV50]

Ahh bugger I've contacted the ebayer apparently they have said it is good for mild steel but I'd prefer to play it safe.

Yeah those clocks look more inkeeping with the car than the mazda items which will be a little awkward to mount and still be within IVA standards and viewable. I take it the vehicle speed will come from the mk2 speed sender and go both to the box of tricks and the ecu?

I guess the LCD is for the tachometer, I think you have to have one of them for road legality don't you?

[skov]

My thoughts exactly on the MX5 clocks. I like them in the 5, but I think they'd look a bit gash in the roadster, and would be a pain the proverbial to fit!

I was going to use individual after-market gauges and warning lights, and was browsing ebay for some when I saw the mini clocks.
It would have been easier taking that route, but I like a challenge, and it gives me an excuse to design some electrickery :D

That's right about the Mk2 speed sensor. Although it doesn't appear to go into the ECU on my wiring diagram, maybe they only did that for later models?

Do you mean 'odometer' on the LCD? I'm not sure if you need one or not to be honest :confused: I can't remember seeing anything about it in the IVA manual.
I do want one though, and I'm pretty sure I can get it displayed on the LCD with a bit of work.

[CTWV50]

My thoughts exactly on the MX5 clocks. I like them in the 5, but I think they'd look a bit gash in the roadster, and would be a pain the proverbial to fit!

I was going to use individual after-market gauges and warning lights, and was browsing ebay for some when I saw the mini clocks.
It would have been easier taking that route, but I like a challenge, and it gives me an excuse to design some electrickery :D

That's right about the Mk2 speed sensor. Although it doesn't appear to go into the ECU on my wiring diagram, maybe they only did that for later models?

Do you mean 'odometer' on the LCD? I'm not sure if you need one or not to be honest :confused: I can't remember seeing anything about it in the IVA manual.
I do want one though, and I'm pretty sure I can get it displayed on the LCD with a bit of work.

Yeah it's wierd on my 95 mx5 the speedo runs off of a cog driven cable but then there is a speed sensor in the clocks that feeds the speed back to the ecu! god know why, I can't believe the ecu is working out what gear your in and adjusting engine parameters based on that and if so why are they using a cog driven speedo?? It's wierd!

Yes sorry Odometer. Wouldn't there be some sort of protection against clocking a modern mini. Do the clocks store the mileage or is that the mini ecu's job?

[skov]

Yes sorry Odometer. Wouldn't there be some sort of protection against clocking a modern mini. Do the clocks store the mileage or is that the mini ecu's job?

I'm not sure how the mini works at the moment.
I've been playing around with clusters from current model Korean cars for a client recently and they're nice and basic - the odometer is stored in a little EEPROM in the cluster (which incidentally you can change quite easily!)
The mini is rather more complicated. From reading up on them, you cant just swap clusters from one car to another as they are coded to each individual vehicle. Apparently you have to get a replacement cluster reprogrammed by BMW before it will work in your car.
A bit more research required I think!

[skov]

That's enough of electrickery for now... Back to the metal bashing!
This week I have mostly been sorting out my seat mounting.
I won these on ebay a few weeks back for the princely sum of £27 each:

https://lh5.googleusercontent.com/-UP0G6tUukoY/TdZeQt00qnI/AAAAAAAAHNE/Iougr6AQeOc/ebay_seat2.jpg

After nearly a month of excuses from the seller they finally arrived (much to my joy and surprise!).
In the meantime I'd been trying to win some cheap runners, after many failed attempts I finally bit the bullet and bought some new ones from kitparts direct.
Again, they took ages to arrive, but not nearly as long as the seats thankfully (why is it so hard to stick something in the post once you've sold it???).
The mounting holes in the runners were well off where I needed them, but a spot of drilling soon fixed that.

https://lh6.googleusercontent.com/-09GTHwyuR28/Tg95HVS9WAI/AAAAAAAAHU0/J-e9FEE71Y0/s800/seat_runners.JPG

I had originally intended to weld 50mmx3mm flat strips into the chassis to mount the runners on and had them cut to length ready.
As it happened I couldn't mount the runners flat on the floor as the adjusters got in the way so I used 25x25mm box section instead:

https://lh4.googleusercontent.com/-SOUMbcSA9ts/Tg95NaYnWSI/AAAAAAAAHU8/XU0062AvGVk/s640/seat_rails.JPG

I'm actually glad I didn't mount them as I had planned as after fitting the seats I popped my scuttle on top of the chassis.
I didn't realise quite how high it sat - if the seats were any lower I doubt I could see over it, and as it is it's going to be marginal. Might have to borrow one of the kids booster seats.

The seats themselves are a very tight fit in the chassis.
They only just squeeze between the rails, and I think I may have to trim a little off them once I've added the ally panels to the tranny tunnel.
One potential issue with using the MX5 for a donor is that you have to flare the back of the tranny tunnel out as the input to the diff is offset.
This means my seats won't go all the way to the seatbacks, stopping a few inches short.
Luckily for me I'm a bit, erm, vertically challenged, so not a problem.
I suspect most of my mates are going to struggle to drive it though. Nevermind!

https://lh6.googleusercontent.com/-ShF4kfg-rSM/Tg-QDkp4q-I/AAAAAAAAHVg/K_P_yq2DGlM/s640/seats3.JPG

[skov]

Another pic:
https://lh5.googleusercontent.com/-6T7MF2sHxwQ/Tg-QCHs9tVI/AAAAAAAAHVc/PdtoHwFeDB4/s640/seats.JPG

[CTWV50]

I think I won't bother with seats then!:D Nice progress post, inspiring.:rolleyes:

[skov]

More progress tonight.
I've been studying Saturns build pics and shamlessly knicked their idea for how to do the steering wheel/column support.
It feels great having seats and a wheel in the chassis, it makes sitting in it and going brum brum very satisfying indeed :D

https://lh3.googleusercontent.com/-GjbDJklJLHg/ThN06Ybq0_I/AAAAAAAAHWk/jjwPISDFI-4/s640/S5032568.JPG

https://lh4.googleusercontent.com/--q83eVhreEc/ThN06Y0zV3I/AAAAAAAAHWg/pLgWVAJ46as/s640/S5032570.JPG

Ideally I would have liked the steering wheel a bit lower, but that blooming TR9 gets in the way.
I tried putting the column below it first, but then there was no room for my knees :rolleyes:

[CTWV50]

Looks good where did you get the bearing from?

[MarkB]

Skov, The rhs you have got to mount the seats on will need crush tubes through the rhs so the bolts can't crush the tube..I'm sure IVA will want evidence of it even if it's only a photo while the chassis is being made.

Mark

[skov]

Thanks Mark, didn't think of that.
Any idea how thick the walls of the crush tubes need to be?

[AshG]

skov i cant belevie you scrapped your donor in that state. the roof/wings bumpers and boot lid would have netted you another £400 then the lights and loom plus the subframes another £250 odd. your a mad man!

[AshG]

forgot to mention your steering wheel is way too high its almost at eye level looking at it.

[skov]

skov i cant belevie you scrapped your donor in that state. the roof/wings bumpers and boot lid would have netted you another £400 then the lights and loom plus the subframes another £250 odd. your a mad man!

To be honest, I was getting peed off with it taking up my parking space, and the neighbours making snide comments...
The donor looks loads better in the pics than it really was too. The bonnet was full of dents, the wings full of rust, the hood full of holes, and the bumpers full of cracks!
Plus it was all badly painted by what I can only assume was a monkey with a rattle can.
I paid £500 for it and got £750 back so I'm happy enough :D
Still got a few bits I could sell, but I've lost interest now. I might get round to it next time build funds are running low :rolleyes:

I'm not quite happy with the steering wheel height either. Not sure how to get it lower though :confused:
If I go any lower the column hits TR9, and if I go below TR9 there's no room for my legs.

How high is the sierra steering wheel? Can someone measure from the centre of the wheel down to the floor for me please?

[CTWV50]

Build it as it is for the IVA then lower it and use a smaller wheel and get rid of the thick mx5 steering column and switch gear. Maybe then you can use a removable steering wheel to get in and out.

[AshG]

go above tr8 by putting the bearing above tr8 :D that will bring it down and give you enough deflection in the steering shaft not to worry about having a collapsable mechanism in the column. i would do it now as it will be a pain in the ass to sort out later. how it is now will never pass iva as your column is dead straight from the steering rack up to the wheel which is lethal in a crash

there is about 3mm between the column on mine and tr9 so i think you can still get it a bit lower without mods

[skov]

go above tr8 by putting the bearing above tr8 :D

I think that's my current plan. I ordered this variant of the bearing today, so I can play about with it sat on top of the rails:

https://lh4.googleusercontent.com/-LgP5lo-K7ww/ThYUCqEve3I/AAAAAAAAHW0/ijjTIELqWGA/steering_bearing.jpg

I've got about a 5 or 6mm gap between the column and TR9 at the moment, so could drop it a little more without mods, but not enough to get the wheel where I want it :rolleyes:

[skov]

I popped out to the garage last night with the intention of spending 20 minutes or so playing with the steering wheel position.
I may have got side tracked, and emerged a couple of hours later with my build looking like this:

https://lh5.googleusercontent.com/-IcWUdPWCFD8/ThalD7RLfjI/AAAAAAAAHXM/HKcfIVgncuA/s640/S5032566.JPG

I'd been speaking to Spud earlier that day about moving the whole steering column above the top rails and he made the very good point that I need to be careful about the shaft interfering with the alternator and engine mount.
So I thought I'd better stick the engine in there!

If anyone is wondering:
Yes - you can put the MX5 engine on the table, then drop the chassis over it.
No - I would NOT recommend doing it that way! Particularly if you're short on space to manoeuvre, and don't have anyone to help...

It did go over the engine just, but involved a lot of faffing, swearing, grunting, sweating, and removing bits off the engine with one hand whilst holding up the chassis with the other :rolleyes:

Hopefully I'll have time to fabricate the engine mounts, then finalise my steering system over the next few days.

All the recent MX5 talk on the forum is really getting my enthusiasm going :cool:

[CTWV50]

Bloody Hell John!!!!:D

[CTWV50]

Is that the engines installed height and position?

[skov]

Is that the engines installed height and position?

No, it's just sitting rougly in position in the photo above.
I'll take some more pics when I've finalised it and made the engine mounts.

[skov]

Time for a quick update.
Since getting the engine in the chassis a couple of weeks ago I've made a start on the engine mounts, and added some plates for the handbrake lever to bolt on to:

https://lh4.googleusercontent.com/--cpNzBS3--0/Th4kgymO8TI/AAAAAAAAHZE/VFTosaOGxt4/s640/S5032574.JPG

https://lh4.googleusercontent.com/-48YmvoMGdZk/Th4kYfWQDqI/AAAAAAAAHY0/u8ZE1ocLBQA/s640/S5032573.JPG

https://lh3.googleusercontent.com/-I3P_JLwREkA/TictfKmfHHI/AAAAAAAAHfI/gbjRVS6VbFg/s640/er2.JPG

https://lh4.googleusercontent.com/-p4ZNlQ6omME/Tictea9vKfI/AAAAAAAAHfE/FOUH92pOXDc/s640/handbrake_lever1.JPG

[CTWV50]

Looks really good, my mind is back on the build now after a little break. I was thinking as I still have my donor I was going to cut out the section of tunnel that the handbrake mounts to and weld it into my chassis tunnel with a bit of fetling. But failing that it looks really simple to mount otherwise!

Have you got the engines final install height now?

[skov]

Yep, I've got the sump flat on the table and raised the chassis 40mm above it.
I don't like the idea of the sump being that low below the chassis, but if I raised the engine any higher it wouldn't fit under the bonnet.
Height-wise it's going to be pretty blooming tight as it is. I haven't got a bonnet yet, but if I put the scuttle and nose cone in place and put a straight edge between them it looks like the bonnet will just skim the intake manifold.
I'm guessing/hopeing that once the engine mounts take the weight of the engine they'll compress slightly leaving me a mm or two clearance!

[BORNXenon]

If there is any clearance whatsoever then your engine isn't big enough!! :D

[skov]

If there is any clearance whatsoever then your engine isn't big enough!! :D

Good point!
In fact there's tons of clearance on the passenger side of the engine bay, I'll have to fill it with a mahoosive turbo :D

[sven8t4]

Ooooooooh Good Plan..... I was thinking post SVA of a Supercharger? Ex BMW '0 Series' aka Mini....

[twinturbo]

Eaton M45,

I used to have an M62 sitting on my desk many moons ago.

TT

[skov]

Stop planting ideas into my head, I just spent a couple of hours looking at different charger options.... must resist... at least until after IVA anyway!

[robo]

Good point!
In fact there's tons of clearance on the passenger side of the engine bay, I'll have to fill it with a mahoosive turbo :D

Or an extra 4 cylinders.

Bob

[skov]

Thought I'd have a go at mounting the gearbox last week.
I'm not sure I'm quite happy with what I've done, but I can't think of a better way...

After a lot of umming and arring I made something sort of like the main engine mounts, but smaller, and using a rubber engine mount from a classic/original mini.

First I tacked a plate onto the base of the tunnel with the mini mount attached:

https://lh3.googleusercontent.com/-eSDpgo4bgR4/Tiv_UzaQLtI/AAAAAAAAHgg/IfZN_DkS2CE/s1024/gearbox_mount3.JPG
https://lh6.googleusercontent.com/-nXxGJ6IUlg8/Tiv_Zyoj9LI/AAAAAAAAHgo/kh1qIKT4uZs/s1024/gearbox_mount4.JPG

Then I bolted a plate onto the top of the mini mount, and another on onto the bottom of the gearbox, and tacked in a couple of plates between the two.
Finally I removed it, added some sides and fully welded and this is what I ended up with:

https://lh5.googleusercontent.com/-y1i9YGQWUKs/Tiv_TkVHV5I/AAAAAAAAHgY/-szQDvZZ7F4/s1024/gearbox_mount1.JPG

And here it is back in the chassis:

https://lh4.googleusercontent.com/-SvJTnJla1FQ/Tiv_ZuJqRvI/AAAAAAAAHgk/dHWOKDlDVAA/s1024/gearbox_mount5.JPG

Does that look like a vaguely sensible way to do it?

[CTWV50]

Does that look like a vaguely sensible way to do it?

I have no idea!:)

[sven8t4]

looks good to me ;o)

[skov]

Woo hoo - Saturn have just released their MX5 build guide :D
Just been looking through it, and it doesn't look like my build has deviated from their design too much!

They've also got the MX5 parts on their webstore too now. Just ordered myself a set of wishbones :cool:

[CTWV50]

Oh yeah! Oh yeah! So happy! :D

[poshguy]

can you link to saturns build guide as i cant seem to see it cheers

[PorkChop]

can you link to saturns build guide as i cant seem to see it cheers

It's due to be posted up on Saturn's site early next week apparently, although you can email Andrew to get it this weekend.

[skov]

Have at this thread for details, post #149

http://www.haynes.co.uk/forums/showthread.php?t=5753&page=15

[skov]

I've been suffering from a severe case of the man-flu for the past week so haven't done much on the build...
I managed to brave a few hours in the garage today though and have (possibly) finalised my steering design.
After lots of playing around I've decided to keep it much the same as my first attempt, but have managed to drop the height of the steering wheel by an inch or so. Ideally I would have liked it lower still (and possibly a couple of inches futher forward) but I can't easily acheive that without cutting a big hole in TR9, or going above TR8 which would mean taking a rather tortuous path through the engine bay.
So basically all I've done is cut the top rail of my column support off and welded a new one in slightly lower, getting rid of the gap I had previously left between TR9 and the column, so the column just touches it.

Whilst I was at it I also added a little plate to TR9 so I can bolt a 38mm exhaust clamp to it to add additional support for the column (I shamlessly nicked this idea from Westfield who do something similar on their MX5 based 7):

https://lh5.googleusercontent.com/-nOC7flR2-sI/TjQs3u8KCuI/AAAAAAAAHhk/pBdny7iAJJA/s640/30072011_steering5.JPG


I've been wondering for a while how to link the mazda column to the escort rack and had a bit of a brainwave this weekend. It's possibly a silly idea, and a waste of a perfectly good sierra column, but...
I started off with the MX5 steering rack linkage, which I cut down on one end:

https://lh6.googleusercontent.com/-4ehfytLY4_k/TjQsokpjE4I/AAAAAAAAHhQ/KyDktQNZjRQ/s640/mazda_rack_coupling_cut_down.JPG

I then dug out a Sierra colmn I had lying around, chopped it in half and mated the two together:

https://lh3.googleusercontent.com/-gV3v3yyDp7Q/TjQsm0Rzw5I/AAAAAAAAHhI/R52hesPiYoE/s640/mazda_coupling_mated_to_chopped_down_sierra_column .JPG

So the Mazda end mates with the lower part of the MX5 column, and the Ford end mates with the steering rack using one of RallyDesign's Sierra-to-escort linkages:

https://lh6.googleusercontent.com/-tag0eiVFXx0/TjQsuL2Fq8I/AAAAAAAAHhU/sm9UnxxeTWs/s640/escort_to_sierra_coupling2.JPG

It all seems to fit nicely, and feels great watching the rack move when I turn the steering wheel. Can't wait to get it rolling now!

[skov]

Some more pics (damn the 4 pics per post limit!)

https://lh5.googleusercontent.com/-OeY9Z3zDWWw/TjQswtriRYI/AAAAAAAAHhY/5vy19CwKP-E/s640/30072011_steering2.JPG

https://lh6.googleusercontent.com/-UODdx5U9ry8/TjQs1iUvjnI/AAAAAAAAHhg/yZfGCr4X5jE/s640/30072011_steering3.JPG

https://lh4.googleusercontent.com/-edcBQFhyQCI/TjQs6HUr5TI/AAAAAAAAHho/kaZRvb644ak/s640/30072011_steering4.JPG

https://lh4.googleusercontent.com/-hE2TGQmzJ6Q/TjQs7roRp4I/AAAAAAAAHhs/vKxBa-Ki4Jc/s640/30072011_steering6.JPG

[skov]

And Skov said, Let there be light: and there was light.
And Skov saw the light, and it was good.

After several months of working in a dimly lit garage I finally pulled my finger out and did something about it today.
Previously the roof of my garage (or hanger as it was once called) was crammed full of model aircraft and assorted sh!t, and light was supplied by a couple of badly placed 60W bulbs:

https://lh5.googleusercontent.com/-LcjU57-jHfA/TeQQtBAEfHI/AAAAAAAAHQE/euAX5eZCZVc/s640/chassis_sideways.JPG

All that junk has now been replaced by a couple of strip lights.
Cost of lights: £25.98
Being able to see what I'm doing: priceless :D

Made a huge difference, can't believe it I didn't do it months ago!
Slightly miffed to find my squadron was full of hundreds of tiny burn holes when I removed them :rolleyes:

https://lh3.googleusercontent.com/--jft2kIkI0A/TlFyOiED8TI/AAAAAAAAHmI/zyutvCG55Rw/s640/let_there_be_light.JPG

[CTWV50]

It's always nice to be able to see what your doing, as I realised when I bought a new auto dimming welding mask!!:D

[skov]

It's always nice to be able to see what your doing, as I realised when I bought a new auto dimming welding mask!!:D

I spotted one of those in Halfords yesterday and had to resist purchasing it.
Doesn't seem much point now I've done most of the welding.
If I start another big welding project I'll definitely invest in one, it's a pain in the &rse having to nod violently to get my mask to fall over my face when my hands are full!

[skov]

Got my VIN plate from AdrianH today.
My crappy photo doesn't do it justice, looks the dogs donglies :cool:
Just need to decide where to stick it now.

https://lh4.googleusercontent.com/-s-ZT4Y8veR8/TlOhEo52a3I/AAAAAAAAHmg/ZOdSHhufKUY/VIN_Plate.JPG

[sven8t4]

without sounding daft does anyone know what the breakdown of the charactures means?

[Bonzo]

It's my best guess that the SABT is the departments postcode SA** *BT

The VRO probably means Vehicle Rigistration Office & the rest is probably a random set of characters.

Best that I can dream up :D :D

[sven8t4]

Good enough for me lol

[SeriesLandy]

AshG reconed it is sad awkard bastard trying vehicle registration.

[Bonzo]

AshG reconed it is sad awkard bastard trying vehicle registration.


:D :D :D

Could well be right.

[skov]

The VIN plate kindly provided by Adrian went into my chassis this week.
I decided to stick it on the inside of U6, which I think is ok.
Rather than weld the plate onto the face of U6, which Mr IVA Man may or may not approve of, I got the angle grinder out and cut a section out of U6 the same size as the plate. Then I welded it in and ground/sanded down the welds so it's nice and flush, and will hopefully (once I've finished blending it in) look like the number is engraved straight into the chassis member :)

https://lh6.googleusercontent.com/-sWyeNrUxzgA/TluEYjYEWlI/AAAAAAAAHpg/V3tCgUOlsK4/vin3.JPG

[poshguy]

Looking good

[skov]

A box of goodies arrived from Saturn this morning :)

https://lh3.googleusercontent.com/-8i5W4cgTi5Q/Tl9Gb6XwzRI/AAAAAAAAHpw/_UTNnE9-fDI/s512/wishbones_arrived.jpg

It's going to be a long day at work today :rolleyes:

[skov]

Had a bit of a play with my bones last night :)
They seem to fit with a bit of persuasion, which means I must have welded my brackets in roughly the right place!

https://lh4.googleusercontent.com/-0l3ZsiR90H0/TmCrkhfpCLI/AAAAAAAAHqE/kN4veDa13Hk/s512/bones5.jpg

https://lh4.googleusercontent.com/-Nglz8kMkTrY/TmCrkghJXJI/AAAAAAAAHqI/JaN434uhwdU/s512/bones4.jpg

( Sorry for the even worse than usual photo quality :o )

[poshguy]

looking good mate

[skov]

Had a productive evening in the garage tonight.
I reworked my handbrake cable guide, and welded on the rear roll bar brackets and headlight mounts, which <fanfare please> means I've just finished all the welding on my chassis! :D

I did try take some pics, but the camera's gone walkabout, and my phone just ran out of charge :rolleyes:

[HandyAndy]

Nice one Skov :cool: its a great feeling to put the mig away & start bolting things to the chassis .

BUT.....have you welded on the little brackets to hold your flexi brake pipes etc? easily overlooked :eek: guess how I know :D

cheers
andy

[skov]

Nice one Skov :cool: its a great feeling to put the mig away & start bolting things to the chassis .

BUT.....have you welded on the little brackets to hold your flexi brake pipes etc? easily overlooked :eek: guess how I know

cheers
andy

Yep, away goes the MIG, and out comes the paint brush :)
I've got about 4 weeks left to paint it before the next baby arrives, just hope the wife holds on for long enough :D

I'm pretty sure I've got all the brackets I need, and yes I did remember the brake pipe ones, thanks though!

[CTWV50]

Well done John you're really ploughing on with it now. I need to pull my finger out!:rolleyes:

[skov]

Don't worry Chris, I'll be up to my elbows in nappies and milk soon, so you should have plenty of time to catch up!


Here's a couple of poor quality pics of my completed chassis (don't know where the bloody 'ell my good camera has gone :mad: ):

https://lh6.googleusercontent.com/-wxxrzzzqu7Q/TmdISy6H1xI/AAAAAAAAHqc/BrDeOYvNMCA/s800/chassis_fully_welded1.jpg
https://lh5.googleusercontent.com/-5-RBXbK912k/TmdIUa80FTI/AAAAAAAAHqs/ncMUhjSvo10/s800/chassis_fully_welded2.jpg

[sven8t4]

Hey Skov,

did you buy or make your suspension brackets?

Sven

[twinturbo]

Best bet is to go to Dave at Rouge engineering..

TT

[skov]

Hey Skov,

did you buy or make your suspension brackets?

Sven

I think I bought them from Talon.

[skov]

I've just reached a major milestone, and have finished painting my chassis:

https://lh5.googleusercontent.com/-7wZGwXMyNIw/Togb-GHcxPI/AAAAAAAAHvc/BKVcJeZOVdY/s640/S5033027.JPG

https://lh5.googleusercontent.com/-T99ifGOhQhs/Togb56b5jJI/AAAAAAAAHvM/RWmihZOERJQ/s640/S5033020.JPG

I've spent the last week or so racing to get it completed before the imminent arrival of the pitter patter of little feet!

I think I'll be taking a break from the build for a while now to concentrate on sleepless nights, dirty nappies, and my helping out my long suffering wife - safe in the knowledge my chassis isn't going to rust away over the winter :)

[james3004]

looking good John, It'll soon be rolling;)

Good luck with the new addition When he/she comes

[twinturbo]

Good luck.

TT

[skov]

Thanks James/TT.
In theory we've got a week left, but the wife's been feeling some tremors over the last couple of days, so it could be any time now.
I'm kind of hoping it'll all happen tonight so I don't have to go to work tomorrow :)

[robo]

OMG Dont slam any doors:) :) :)

Bob

[HandyAndy]

Chassis is looking great John , nice to see a chassis kit that originally was not being started into a completed chassis :cool:

All the best for the new arrival, soon have a little helper passing you the spanners :)

cheers
andy

[TheArf]

Looking good, hope all goes well has anyone managed to build a three seater yet

Arfon

[skov]

Looking good, hope all goes well has anyone managed to build a three seater yet

I'd need more than a 3 seater, already got a few little 'helpers'! (this one looks like it's going to be another girl, so no help there, lol)
I did think about making an 8 seater by stretching it out and adding another 3 rows of seats, but my garage isn't anywhere near long enough :D
I think I'll just have to set up a rota for who gets to go in Dad's sportscar while the rest are in Mum's bus. There were no end of arguments about who's turn it was in the MX5 before I got rid of it!

[skov]

I spent ages trying to find some double clips for the fuel lines, then stumbled upon these little beauties:

https://lh5.googleusercontent.com/-iSRC7VoIxlE/Tot0g7qeW0I/AAAAAAAAHxQ/kLvkNJ7evYo/tripple_pipe_clip_1.jpg

https://lh3.googleusercontent.com/-Fyy7Q4bK9Sk/Tot0hJAXadI/AAAAAAAAHxU/VbB-mjQOi30/s720/tripple_pipe_clip_2.jpg

They're designed for two 8mm pipes, and one 4.8mm pipe, which is perfect for running the fuel and rear brake lines down the tranny tunnel :D

Only problem is they weren't particularly cheap (~40p each), and I had to buy a hundred of the buggers!
...so I should have a few spare if anyone else wants to buy some off me ;)

--------------------------------------------

EDIT: I've now sold all my surplus clips!
Here's the details if anyone wants them:

Manufacturer: Jetpress
Part# CAC446-NAT
Supplier: http://www.comdir.co.uk/

---------------------------------------------

[twinturbo]

I would be interested in a suitable qty..

good luck for the iminent sleep loss.

TT

[rdodger]

Good find!

I will take a few off you. 10 should more than do it.

How would you like paying?

[HandyAndy]

Those clips look ideal, very neat installation :cool:

As TT says, are you on the "countdown" yet :) all the best to you & your family .

cheers
andy

[skov]

Thanks Handy, not quite in the final countdown, but getting dangerously close now! She's due on Saturday, so could be any time :eek:

[skov]

Here's the mounting info for them, I'm planning to run an ally strip down the tunnel to attach them to:

https://lh4.googleusercontent.com/-A2LoJwhflmY/TouId__5O-I/AAAAAAAAHxo/JBDbXx1np9w/pipe_clip_drawing.jpg

[robo]

That clips the dogs danglers. I was thinking of tack welding some of this down the entire length of the tunnel prior to powder coating to save drilling the shite out of the chassis for cable and pipe clips it comes in loads of different widths.

http://dcssltd.co.uk/index.php?_a=viewProd&productId=1744

Bob

[eSteve]

Skov,

your chassis is looking good. I'm very nearly at a similar stage, all the chassis welding done, just piddling about with brackets for engine, g'box and rad. mounts prior to painting.

Thinking one or two steps ahead, as one does, I already had it in mind to run a strip/channel down the trans. tunnel to secure the 'services' to and your clips look just the job. Like you, I don't fancy drilling too many holes in the chassis to mount stuff on.

The fixings you have sourced look just the like those I had in mind. Thanks for offering your surplus to the forum. Have you any left?

I think 10 would do; spaced at 150 mm (half the width suggested in IVA manual) that number would cover a length of 1500 mm, which is plenty enough to get through the trans. tunnel.

How much and how would you like to be paid?

[twinturbo]

I have some ally angel to act as a services tray to go in my tunnel, that way I only need 2-3 fixings to the chassis and it's a darn sight easier to work with.

TT

[skov]

I've got some 30mm x 3mm ally strip.
Going to run the fuel and brake lines along the top on the drivers side, and the wires along the bottom on the passenger side.
Made a start this evenning, just need to rivet the strip to the chassis, then clip my lines in place :D

https://lh3.googleusercontent.com/-VoCd5rgvBZg/To4exCkwX-I/AAAAAAAAHxw/QF7W_HjnqfA/s640/fuel_clips_in_tunnel1.jpg

[skov]

Just got back from the hospital with the latest addition to our family :D

[rdodger]

Congratulations! :D

[skov]

Thanks Rog!

Looks like that's me banned from the garage for a couple of months :rolleyes:

[will_08]

Congratulations John, all the best

[vmax1974]

Thats great news congratulations

[twinturbo]

Excelent new,

TT

[robo]

Thanks Rog!

Looks like that's me banned from the garage for a couple of months :rolleyes:

You wish:p :p More like two years.

Congratulations.

Bob

[rapidtornado]

congrats on the new arrival, looks like it got it's place in the family before the roadster :p

Just a quick question, where did you manage to find those clips? that's just what I'm after, willing to buy a dozen off you if you still have them

PM if you get chance (in between the nappies and bottles);)

Rapid

[james3004]

Congrats John! :D

[skov]

Thanks all :D

[HandyAndy]

Congratulations John , all the best to you & your now bigger family :cool:


cheers
andy

[K4KEV]

Oooops John forgot to congratulate you on your new bairn (good old noreast talk) during our recent comms.....yea you are gonna be busy the next few months lol
K4

[CTWV50]

Ahaha! Now I can catch up! Congratulations!:)

[skov]

Thank Handy, Kev, and Chris!

No worries Kev, looking forward to receiving that nice shiny tank from you,
almost as much as I was looking forward to the shiny new baby :)

I was thinking earlier I hadn't heard from you for a while Chris. How's the build going? Don't work too hard :p

[CTWV50]

It's coming along slowly, I only get about 6 hrs a week at weekends in the garage, but I have spent ages measuring, checking and getting the rear diff cage suspension bracket etc in the right place. This weekend I'll test fit the diff and finish up on the back end less the rear tub mounting as I think I've changed my mind and go with a fibreglass tub. Then do some more full welding and put it on it's wheels, then I'll do the steering supports and spray the whole frame with weldthrough zinc primer......hmm this is turning into a build thread post...cont. (http://www.haynes.co.uk/forums/showthread.php?p=66831#post66831)

[poshguy]

Congrats on the new addition mate :)

[skov]

Thanks posh!

[skov]

My bonnet and nose cone had been on loan to James3004, he bought them back last night, and as I've currently got the engine in the chassis I thought we may as well check the bonnet would fit over it.
Slightly dissapointed to report that it doesn't :(
The bonnet is one of Saturn's wide scoop ones, and it interferes with the inlet manifold (I'll try to get some pics later).
Comparing pics of the 1.6 and 1.8 engines it looks like the inlet manifold sits a lot higher on the 1.6 then the 1.8
Not sure what to do now, I can't drop my engine any more as it already sits 40mm below the bottom rails.
I guess my options are to make a new manifold, which is probably beyond my skill set, or modify the bonnet, which is going to look a bit poo if I do it...
There's plenty of room to move the engine over towards the passenger side by a couple of inches, and I recon the bonnet would fit if I did that. I don't know if the UJ's in the prop shaft could cope with that though?

[adrianreeve]

Can you not fit the 1.8 inlet manifold?

Cheers

Adrian

[skov]

Sadly not - the 1.8 isn't just a bored out 1.6, it's stretched out lengthways, so the inlet and exhaust manifolds aren't interchangeable.

[spud69]

Hi Skov,

That's a shame with the bonnet and clearance, we did a trial fit with the body work a couple of weeks ago and the bonnet cleared the engine and manifold okay. We may have our engine slightly lower but not significantly, didn't realise though that there was a difference between the 2 engine sizes. There are plenty of 1.8 manifolds on ebay from £25 so that is always an option, if you would rather move the engine towards the passenger side the propshaft UJ's will take up the angle okay. After all that's is what they are designed to do.

The engine could always be lowered with the sump shortened as the original sierra installation for the roadster but we were hoping that this could be avoided with the mx5 engine and wide scoop bonnet combination. I think that in most cases it can be avoided plus it would be a shame to modify the mx5 sump as you have a good substantial cast Ali sump.

Congratulations as well by the way.

Regards......AndyH

[Big Vern]

Hi Skov,

That's a shame with the bonnet and clearance, we did a trial fit with the body work a couple of weeks ago and the bonnet cleared the engine and manifold okay. We may have our engine slightly lower but not significantly, didn't realise though that there was a difference between the 2 engine sizes. There are plenty of 1.8 manifolds on ebay from £25 so that is always an option, if you would rather move the engine towards the passenger side the propshaft UJ's will take up the angle okay. After all that's is what they are designed to do.

The engine could always be lowered with the sump shortened as the original sierra installation for the roadster but we were hoping that this could be avoided with the mx5 engine and wide scoop bonnet combination. I think that in most cases it can be avoided plus it would be a shame to modify the mx5 sump as you have a good substantial cast Ali sump.

Congratulations as well by the way.

Regards......AndyH

When changing MX-5 intakes you need to be aware that the 1.6l intake will not fit a 1.8l and the 1.8l will not fit the 1.6l as the cylinder spacings are different.

Regards BV.:)

[CTWV50]

Oh dear! Can you take a picture so we can see how far out it is? How come the 1.6 is bigger/wider/taller than a 1.8?

[skov]

The 1.6 engine is slightly smaller. The problem is the inlet manifold.
From looking at pictures on the web the plenum chamber appears to sit higher on the 1.6 than the 1.8
I'll take some pictures next time I'm allowed in the garage.

[CTWV50]

Just been trying to compare spuds build images with your's but it's not clear in any of them. Can you drop the engine lower and maybe weld in some sort of sumpguard to the chassis?

[spud69]

The normal scenario with car engine installs into roadsters is to lower the engine and shorten the sump, it was hoped that the Mx5 engine was short enough to avoid this with the larger bonnet scoop. It seems that the 1.8 engine you can but not the 1.6, must say i didn't realise there was such a difference between the two. It is a shame but it does look like the sump can be shortened by 30mm quite easily if required, builders of the Westfield SDV Mazda car have had to do similar after finding they are left with only 30mm of ground clearance to the sump after fitting the engine.

All the Best.........AndyH

[skov]

I was hoping to avoid chopping the sump, but I'll keep that as my back-up plan.
I'll have a play about with the engine position when I've got some more time and decide the best course of action.
Here's some pics for now:

https://lh6.googleusercontent.com/-CXdiAmGTXNM/TqsWU-ivGZI/AAAAAAAAH1o/QnUWyXlzbDk/s640/S5033120.JPG

https://lh5.googleusercontent.com/-S3K-gFjMkFU/TqsWZdiYk9I/AAAAAAAAH2M/5mHip0TqVKo/s640/S5033138.JPG

https://lh3.googleusercontent.com/-5siTHL51tKA/TqsWZgM5h1I/AAAAAAAAH2Q/JUFKNGBzBlc/s640/S5033139.JPG

https://lh3.googleusercontent.com/-mT0GVXbOGS4/TqsWWmwdwxI/AAAAAAAAH18/NH6w_DTVZQg/s640/S5033135.JPG

[MarkB]

Looking at the pictures you have no choice but to lower the engine unless you cut away the bonnet where it contacts the intake and then make up another bump once bonnet is sitting in the right place.

[twinturbo]

Could you make up an adapter plate to match the ports on the 1.6 head to the 1.8 Manifold?

TT

[Davidbolam]

why don't you do an engine swap from the 1.6 to the 1.8. If you look at flyinmiata.com they describe how to do it and let you know which parts are interchangeable. You could sell your 1.6 engine on ebay and probably cover the cost.

The other option could be to look at the universal scoop offered by agm to see if that is large enough to cover the 1.6 engine.

I was going to install the 1.6 engine in my car but may now just go for the 1.8

I suppose there is a market for someone who is able to make an adapter for the 1.6. This is my preferred engine (can bolt on a turbocharger later on quite easily).

http://flyinmiata.com/tech/1.8_conversion.php

[skov]

I did think about swapping for a 1.8, but it's a fair bit of hassle and unless I got a complete 1.8 donor it would be hard to prove that the engine was pre-1995 to avoid having to do the cat test.

Anyways, I've been out in the garage for the last couple of hours and I think I have a solution.
I've moved the engine 30mm towards the passenger side, and 'modified' the manifold. By modified I mean attack with an angle grinder :D
I still need to re-make my engine mounts, and possibly make a new bracket for the throttle cable, but that's not the end of the world, and shifting the engine accross also makes routing fuel and brake pipes down the tunnel a little easier :)

[Davidbolam]

Sounds like a good idea. Can you post some pics? Do you have any photos of the brakets you are using to mount the flexible brake pipes to the chassis at the rear and the routes you have taken for your pipes?

[CTWV50]

Well done John!:)

[MarkB]

The Vodou plugs were made so that the most popular 1.6 engine fits under the bonnet.

[Davidbolam]

Any further news on when the grp will be unveiled?

[skov]

Bonnet now fits!

https://lh3.googleusercontent.com/-nX2ghWJdJm8/Tq-9Ym1lQ0I/AAAAAAAAH7o/3FuGC2OEPI0/s640/S5033118.JPG

As well as moving the engine accross, I had to grind off some of the throttle cable mount.
I think I should be able to add a new threaded hole futher down to replace the one I removed and just mount the throttle cable bracket slightly lower than it would have been:

https://lh5.googleusercontent.com/-Ax-wKVK5NMg/Tq-9cBvJJeI/AAAAAAAAH8E/8Bi_bMyQED4/s640/S5033124.JPG

Moving the engine has also fixed my clearance issue between the gearstick turret and fuel lines, which is nice!

https://lh4.googleusercontent.com/-XCg7hD1IvYU/Tq-9e6-ZWjI/AAAAAAAAH8Y/VDA1hJY2oKU/s640/S5033129.JPG

The propshaft runs at a slight angle down the tunnel, but I don't think it's enough to cause any trouble.
The UJ's are running at about 2.5 degrees, which should be well within their capability.
I'm pretty sure Westfield offset the engine in their MX5 chassis by a similar amount.

https://lh3.googleusercontent.com/-e1QdJCDL68w/Tq-9iZ-ekLI/AAAAAAAAH8w/BGS8MdnRLKM/s640/S5033131.JPG

[Bonzo]

Pleased to see that you have managed to find a solution to your problem Skov :cool:

Looks as if that has worked out nicely, gearbox certainly looks a lot better in the tunnel. :)

Looks as if I will be taking the same route with my Red Top engine, the Saturn wide scoop bonnet clears my engine fine but if I can budge it over a tad, I too will be able to use the OEM inlet manifold & throttle body ;)

[spud69]

That's nice to see Skov, well done you had us a bit worried then. Westfield also chop there sumps to so we have scored there.

Cheers....AndyH

[CTWV50]

Well done John I knew you'd sort it out. :cool: Now all you need to do is comunicate some exact dimensions for locating the engine to me so I can get my engine in before ordering my body work.:D

[skov]

Got to agree with the gearbox position Bonzo, I much prefer it where it is now :)
It was your thread on the red top that gave me the idea to move the engine sideways a bit!

Sorry to worry you Spud.
Thinking about it, I've got about 10 speed bumps on my commute, and I've got a feeling I'm going to end up chopping the sump eventually anyway :rolleyes: glad I don't have to do it just yet though.

Getting exact dimensions from my banana shaped chassis isn't going to be easy Chris, but I'll give it a go.

The only downside with my engine move was that it made the propshaft touch one of the mounting bolts for my handbrake lever (wouldn't have been a problem if I'd put the lever where Spud has).
Just been out in the garage and modified the lever so it's all good.

[CTWV50]

Getting exact dimensions from my banana shaped chassis isn't going to be easy Chris, but I'll give it a go.

Well if you take a measurement from the sump drain nut to BR7 and then one from the top Front Frame rail to the outer edge of the big pulley at the front of the engine we should be good assuming the chassis is raised 40mm above the engine when placed on a flat surface. Let me know if you have a better idea.

Cheers

Chris

[skov]

I've added some pics with dimensions to my album (https://picasaweb.google.com/john.scothern/HaynesRoadsterPart2#) Chris.
Just bear in mind my chassis probably isn't as millimeter perfect as yours!

[CTWV50]

Thanks John but I just get "Sorry, that page was not found." for that link and your photoalbum2 sig link. Nope I think it's not public.

[skov]

Thanks John but I just get "Sorry, that page was not found." for that link and your photoalbum2 sig link. Nope I think it's not public.

Now public!

[CTWV50]

Cheers Mate that's fantastic. Thank you. I'm pretty sure mines not mm perfect either, I know for a fact that it sorta got a tiny bit smaller after fully welding but what are going to do!?! Painting my wishbones at the moment and trying to get it somewhere near, a roller, it's going to help alot for me when positioning the engine.:)

[skov]

No problem Chris. I think there's scope to move the engine back a bit too which will help with bonnet clearance.
You just need to be careful about how much room you leave for the clutch arm.

Funny you should mention painting wishbones, it just so happens I popped to halfrauds this morning to buy some paint for mine!

[CTWV50]

Halfords matt black for mine!:D

[skov]

Hammerite Smooth Black for me.
Also got a tin of Dark Green for no other reason than it was on sale :rolleyes: Might have to use that for the first coat!

[skov]

Just finished fitting my floor :D

https://lh4.googleusercontent.com/-7KyBuJb_2uE/TrpNSCqRAZI/AAAAAAAAH-I/U3kf3RFx034/s640/floor1.jpg

Now I just need to figure out how to get the sikaflex off my hands :confused:
Should have waited until I'd bought a new box of gloves - I won't be making that mistake again!

[robo]

Cellulose thinners if your quick:eek: Nothing else I have tried touches the stuff:(

Bob

[skov]

Bu99er, looks like I'll be living with black hands for a while then :rolleyes:

[skov]

Tank by K4KEV turned up today :D

https://lh6.googleusercontent.com/--Jv4CnApXPo/Trr4xtzlb9I/AAAAAAAAH-g/eM3E8HBJQKk/s640/S5033117.JPG

[K4KEV]

I see what you mean about it being a tight fit:rolleyes:

[CTWV50]

I see what you mean about it being a tight fit:rolleyes:

Are you making any more of these? I'd be interested in one.

[Johno]

How did you get that in...used a shoe horn:) Looks good in place nice and cosy.
Are you going to fit original sender and fuel pump? judging by the photo it looks a little shallow unless you intend to modify the original parts.
We mocked our tank yesterday with the original unit unaltered and pressed them up today.
How many litres will she hold out of curiosity?

Cracking build....Johno

[skov]

Should hold about 7.5 gallons I think, and no I didn't use a shoe horn - I used a rubber mallet :D
It certainly won't be coming out again any time soon!

I got a universal fuel pump and sender off ebay and junked the MX5 one.

[Johno]

Hi John,
I hope you don't mind but seeing as we have no body panels as of yet we used your measurements as a guide to fit an engine in my chassis this weekend.;) We are using the same 1.6 engine from a 91 Eunos to set up the mounts for all our chassis's.
We were gutted to find out your engine fouled the bonnet as we plan to use the same panels. Andy advised me to sit the sump 50mm below the bottom of the chassis rails is yours the same? I have seen somewhere on the internet a modified sump cut short by 30mm but be dammed if i can find it now.. I plan too shorten my sump as we have speed bumps where I live and at work "just ask TSM Locost about the ones at work...LOL...":rolleyes:
We have been following your build with great intrest and only hope you carry on the good work.
Perhaps one day we can all meet up as I believe there are a few other fellow builders around this area.
If there is anything we can do to help in someway don't hesitate to speak to us as you have surely helped us.:)

Thanks from all of us Johno, Simon, Tony, Luke and Martin.

[skov]

Hi Johno and co,
Thanks for the kind comments and whatnot. I've been watching your build(s!) with interest too, at the rate you're going I'm going to be looking to you for ideas and help before much longer!
I've got my sump 40mm below the bottom rails, and bonnet clearance is borderline, so at 50mm you should be alright.
I don't mind you using my dimensions at all - just don't blame me if it all goes horribly wrong :p
If you do find the sump mod link I'd love to see it, as there's some evil bumps round here too. There's a particularly nasty one guarding one of my favourite 'scenic' routes to work. I used to grind the MX5 out every time I went over it, so won't have much chance in the roadster :mad:
An East Anglia meet up sounds good when we've finished building, I'm aiming for spring 2013 if you want to pencil something in the diary!

[Johno]

Hi John,
Found this about Westfield build with sump mod....
http://westfieldmx5.devocht.com/?page_id=74&shashin_album_key=21
Hope this helps.

Johno

[skov]

Thanks for the link Johno - That looks a bit of a pain to do!!
It looks like the engine sits a lot lower in the westfield chassis, so hopefully I'll be able to avoid it!

[skov]

This week I have mostly been panel beating:

https://lh4.googleusercontent.com/-UJesAA9dcrI/Tu3OiPq-WjI/AAAAAAAAIA8/WfDfxJBnxAU/s640/S5033150.JPG

https://lh6.googleusercontent.com/--DK6G2BWHWQ/Tu3OhKbkCoI/AAAAAAAAIAw/uXgWyViFUGA/s640/S5033151.JPG

I'm not particularly proud or happy with how they came out, but they're bonded/riveted on now so they'll have to do!
It's certainly going to look handmade... :rolleyes:

[wylliezx9r]

One thing I've noticed is the length of your headlight brackets. Mine were about that length and i found they fouled on the upper wishbone under load, i had to cut them down and re-fit. Worth checking now so you havnt got to get the welder out at a later stage. I may of course be wrong and they are fine as they are :confused:

[skov]

You had me worried there Wyllie :eek:
I've been out tonight and fitted the front wishbones, upright, and wheel on one side to check!
I think I'm going to be ok - I recon I'd have to lose a good inch off my sump before it becomes a problem!

[skov]

Well it's been a year and a day since I purchased the bible, so I thought I'd post a progress pic.
I'd planned to have it completed within two years, and I'd like to think I'm still on track for that. I may well be deluding myself that I'm half way there, but you never know!

Haven't done too much over the xmas period, but slowly getting all the ali sheet cut to size whilst I still have the build table.
Hoping to get it rolling within the next couple of months.

https://lh6.googleusercontent.com/-wTBgU2n09rk/TwHJXQsvCwI/AAAAAAAAICU/2_DCD2EBI-o/s640/1stjan2012.JPG

[skov]

Johno was complaining I haven't taken any pics for a while, so here you go!

https://lh3.googleusercontent.com/-M9LIPqUyhUQ/TxXtzakcuwI/AAAAAAAAIEk/9hJEbfbRIJI/s640/S5033181.JPG

https://lh4.googleusercontent.com/-mYPYq069fb8/TxXtzl94PAI/AAAAAAAAIEg/lJbXP7lmWrY/s640/S5033183.JPG

https://lh3.googleusercontent.com/-6DCFU0VFF7M/TxXt1DSdMII/AAAAAAAAIE0/kUh1e1GlKn0/s640/S5033185.JPG

https://lh6.googleusercontent.com/-_16FMrtoNzs/TxXt2c7Pc-I/AAAAAAAAIE8/k5hoxCgksS8/s640/S5033186.JPG

[skov]

Seat back, tunnel top, and side infill bits now cut out :D
Which just leaves the rear tub in the ali sheeting department. I'll save that until I've finished fitting out the rear end (and feeling a little more brave!)

https://lh6.googleusercontent.com/-hviNZFk856M/TxyAzScsI4I/AAAAAAAAIFU/tLhUs-iMC-E/s640/S5033182.JPG
https://lh3.googleusercontent.com/-Wp93Pq6uutg/TyMaNs7RHrI/AAAAAAAAIG8/FVsZTVkz3Hg/s640/S5033191.JPG
https://lh6.googleusercontent.com/-7ORJlt-LC7g/TyMaOD8aFaI/AAAAAAAAIHA/M_5NOqs2NHA/s640/S5033192.JPG

[HandyAndy]

Thats looking very nice indeed :cool:

[james3004]

looking good John, You're catching me up rapidly!:)

[Johno]

Very nice indeed....:)
Keep up the piccy's..

Johno

[Gear Monkey]

Looking good! We'll have to come and take a proper look one day soon.

Paul

[skov]

Thanks guys :)
It's starting to feel like it's coming together now. With any luck I should have her on her wheels and looking like a car in another week or two. Can't wait :D

[skov]

Well, it nearly killed me, but I managed to get the chassis off the build table and onto axle stands this evening :)

[skov]

Starting to look like a car now :cool:

https://lh6.googleusercontent.com/-eEjoCC3dmI8/Tyxkq6diJBI/AAAAAAAAIHU/CXgVFaRIG6I/s640/S5033190.JPG

[james3004]

Looks Great John!
If you needed a hand getting it off the build table you should have given me a call I'd have popped over to give you a lift!;)

[skov]

Looks Great John!
If you needed a hand getting it off the build table you should have given me a call I'd have popped over to give you a lift!;)

Bugger, didn't think of that! Probably would have saved me wrecking my shoulder an crushing my toes in the process :rolleyes:
Thanks anyway James :)

[skov]

No progress on the car this weekend, but I did manage to build something else:

https://lh4.googleusercontent.com/-RG6W1kA9Ezo/Ty5q86zqfvI/AAAAAAAAIIw/BYW9QedMdIs/s512/S5033195.JPG

https://lh6.googleusercontent.com/-A1VGJxnk2LQ/Ty5q0__wRaI/AAAAAAAAIHw/IOTXRaiAeJ0/s640/S5033196.JPG

Is it just me or does anyone else turn into a big kid when it snows :D

[tkpm]

Whats Snow? :rolleyes:


Terry

[skov]

I take it you haven't been blessed with any down in Devon :p
We woke up to 4 or 5 inches of it. Just a shames there's no hills out here in the Fens :(

[michael92]

haha! awesome! looks like the hitcher off the mighty boosh!

[tkpm]

The sun is shining, the dog been for a 5 mile walk. It's realy nice winters day.


Terry

[stew]

haha, brilliant john. :)


we have no snow where i live in scotland, but other areas do have. seems like its been south of the borders turn this time!!!

good progress with the car btw! :)

[Johno]

Car looking sweet John,
I notice on the photo you have negative camber on your rear wheel. Do you still have plenty of adjustment on the lower wishbone even with a half locking nut in place to take this out?
The reason I ask is Lukes car is the same as your photo but has little adjustment left to take this out.
Is it possible for you to measure the centres of both top and bottom wishbones (centre of bush to centre of hub upright fixing point) please...:)
I just want to check that our wishbones are the same as yours as we made ours to SSC drawings and I know yours are from Andy..

Cheers Johno....ps I think we had the worst of the snow in our area as I had to dig our cars out..