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-   -   Rosco's haynes Build (http://www.haynes.co.uk/forums/showthread.php?t=13517)

SeriesLandy 22nd June 2015 10:06 PM

Looking great like normal.
When it comes to iva a few people have been caught out on radius with the long acre mirrors.

I was also worried about the handbrake height but it seems to make a perfect arm rest.

Rosco 23rd June 2015 08:02 PM

Cheers mate, yeah I'm going to have to use edge trim I think,

As for the handbrake, it's not to bad I don't think, where else you going to put it without making the cable a nightmare

SeriesLandy 24th June 2015 07:22 AM

One of the other companies has it in the passenger side against the tunnel but the cable routing would be hard as you say. It's quite tight as it is now.

Rosco 27th June 2015 08:24 PM

Well stripped my car down this week and my mate has finished welded it, just a bit of weld splatter to get off then everything's off for sandblasting and powdercoat



The vin number my dad milled for me



Ordered a billet sump and HD clutch springs from AB Performance




Rosco 27th June 2015 08:24 PM

Baffle plate and new oil pickup



Clutch springs



Also got my aluminium panels lazer cut instead of getting the jigsaw out, the floors 1.5mm and the rest 1.2mm, all 5251 sheet

The big hole will sit under the engine, this will have rivnuts fitted and a removable section bolted on


Rosco 28th June 2015 08:36 PM

Got my sump fitted today, engine looks like brand new inside, the new pickup was a little tricky to locate, but got it on in the end






Rosco 7th July 2015 09:25 PM

Got my carbon fibre tube that I've been waiting for today so did a bit more on my gear lever









To say I'm happy with how it looks is an understatement, well happy with it! I'm going to get all the aluminium bits anodised to

Rosco 12th July 2015 08:10 PM

Needed a tool to strip my diffs down so drew one up and made it at work quick, 30mins total








Rosco 12th July 2015 08:10 PM



Fitted perfect, I had to use the air good and heat to get them out though, was a hot sweaty oily job so no pics I'm afraid

Offered my floor up to see how well it fit, perfect, was well happy, as my chassis that I built with a tape measure matches a laser cut panel





All my small parts blasted ready for powder coat next weekend


Rosco 12th July 2015 08:11 PM

Got my fuel tank







Testing for leaks



Only thing is my mate who made the tank has dressed the welds and sanded the tank so I think I'm going to get it powder coated

Rosco 12th July 2015 08:11 PM

Rear seat panel



Tunnel sides


Rosco 13th July 2015 07:25 PM

Made a few modifications to my bead roller, welded a handle on to apply the roller pressure and swapped the bottom wheel for a plastic one as the metal one was a bit heavy on the aluminium



Engine hatch marked out



Finished panel, I was a bit worried about ruining it, but it's turned out perfect, tomorrow night I'm doing the big floor panel :D


Rosco 14th July 2015 07:57 PM

Got my floor beaded tonight with the help of my dad, could of done with another set of hands really as it's quite a big sheet

Turned out quite well, one bits a little dodgy but I will give it a little tap before I rivet it on





What it looks like from the inside


vmax1974 15th July 2015 08:07 AM

Looking good as usual loving the rollers any chance you put us a set of drawings together for the roller

Davidbolam 15th July 2015 12:10 PM

Really nice build there. I have been following all of your thread. I like the enclosed bottom. The only question I have is where will all the hot air go from the radiator etc? Are you going to vent the sides of the body?

Rosco 15th July 2015 08:59 PM

Quote:

Originally Posted by vmax1974 (Post 101142)
Looking good as usual loving the rollers any chance you put us a set of drawings together for the roller

I could do pal, if I was to make it again I would do it a bit different tho

Rosco 15th July 2015 09:01 PM

Quote:

Originally Posted by Davidbolam (Post 101143)
Really nice build there. I have been following all of your thread. I like the enclosed bottom. The only question I have is where will all the hot air go from the radiator etc? Are you going to vent the sides of the body?

Urm, I'm not really sure to be honest, not really thought about it, :confused:

Could it go down the tunnel and out of the boot floor, above a diffuser? Or yeah I could vent the rear of the side panels and the bonnet

Rosco 19th July 2015 05:30 PM

Dropped my chassis and everything off at the powder coaters yesterday morning and collected it this morning, well happy with it! I feel like the ends now in site!








Rosco 19th July 2015 05:31 PM




NeilW 19th July 2015 05:47 PM

Looks awesome mate, the pedal box is really nice. When you taking orders?? :D

K4KEV 19th July 2015 06:52 PM

Well tidy mate, should command big dollar when and if you sell it. (after you have had some fun of course:D )

voucht 20th July 2015 03:36 PM

Quote:

Originally Posted by Rosco (Post 101145)
Urm, I'm not really sure to be honest, not really thought about it, :confused:

Could it go down the tunnel and out of the boot floor, above a diffuser? Or yeah I could vent the rear of the side panels and the bonnet

As I've already said, this one of the finest builds I've seen, and week after week, it is constantly amazing. I just love the pedal box too!

About the cooling, I second David on that: plan for vents to let the air flow go out.

Also, I don't know if your bike engine is oil-cooled, but whatever it is, I think you will need an oil cooler. On bikes with no oil cooler, I've learnt that the airflow on the sump is enough to cool down the oil. Here your sump will not receive any airflow and there is a risk of oil overheating.

Hope this will help :)

norton 20th July 2015 03:53 PM

That looks stunning!

I know this is always a cheeky question to ask but, would you be happy to share the quoted cost to coat all of that?

Rosco 20th July 2015 10:32 PM

Quote:

Originally Posted by NeilW (Post 101172)
Looks awesome mate, the pedal box is really nice. When you taking orders??

Haha thanks, your not the first, once I've got the car done and tested it I'm going to get a batch made up

Quote:

Originally Posted by K4KEV (Post 101174)
Well tidy mate, should command big dollar when and if you sell it. (after you have had some fun of course )

Cheers, don't think I will ever sell it, but I've joked with my dad about building a helicopter so we will see :D

Quote:

Originally Posted by voucht (Post 101182)
As I've already said, this one of the finest builds I've seen, and week after week, it is constantly amazing. I just love the pedal box too!

About the cooling, I second David on that: plan for vents to let the air flow go out.

Also, I don't know if your bike engine is oil-cooled, but whatever it is, I think you will need an oil cooler. On bikes with no oil cooler, I've learnt that the airflow on the sump is enough to cool down the oil. Here your sump will not receive any airflow and there is a risk of oil overheating.

Hope this will help :)

Cheers mate, I feel like I'm getting somewhere now as the last few months has been a bit slow, I've got loads to do now so hopefully there will be daily updates!

Yeah I think your right with the cooling, I'm going to have oil temp on my dash so will see how it go's, it's only got a water/oil cooler, I could always swap the under cover panel for a louvered one, will have to make a louver tool then ;)

Quote:

Originally Posted by norton (Post 101183)
That looks stunning!

I know this is always a cheeky question to ask but, would you be happy to share the quoted cost to coat all of that?

I got it done cheap by my mates brother, but I would guess about £350, I think it's well worth it as the amount of time I've spent on it, there's not one run on it, also it doesn't build up on the edges like normal paint

Rosco 20th July 2015 10:34 PM

Got the car spun over tonight and got on with marking the rivet holes out, I've gone for 4mm rivets at 45mm spacing, I'm bonding it on to!

I marked the rail centres on first then used a set of dividers to mark the spacing, wasn't as bad as I thought it was going to be and 45mm worked out nicely everywhere which was good for my OCD!





I started drilling a few holes at the back and worked up to the next cross rail, I had brought some cleco pins and glad I did there perfect for the job
Because I had bead rolled the panel it wasn't as flat as a plain sheet, but it pulled flat as I worked my way along



20 cleco pins fitted


Rosco 20th July 2015 10:35 PM

Then I drilled all the holes In between, I will get on the next section tomorrow hopefully


SteveH1 21st July 2015 08:10 AM

Faip play cracking build
Where did you get the colecos was it online can only seem to see them on ebay usa.

voucht 21st July 2015 10:24 AM

Quote:

Originally Posted by Rosco (Post 101185)
Yeah I think your right with the cooling, I'm going to have oil temp on my dash so will see how it go's, it's only got a water/oil cooler, I could always swap the under cover panel for a louvered one, will have to make a louver tool then ;)

If you will have a water-to-oil cooler, you certainly won't need a louvered one (air-to-oil if it is what you mean), as the water-to-oil coolers, like Laminova coolers, are very efficient.

flyerncle 21st July 2015 03:17 PM

LAS Aerospace for cleco pins,good price and delivery don't forget the pliers too.

tkpm 21st July 2015 07:14 PM

There made just down the road from me

LAS Aerospace Ltd
Okehampton
Devon
EX20 1UA
01837 658081

Rosco 21st July 2015 10:35 PM

Quote:

Originally Posted by SteveH1 (Post 101188)
Faip play cracking build
Where did you get the colecos was it online can only seem to see them on ebay usa.


I got them off ebay, but looks like i paid about double compared to the las aero thats been mentioned :mad:

Rosco 21st July 2015 10:37 PM

Quote:

Originally Posted by voucht (Post 101189)
If you will have a water-to-oil cooler, you certainly won't need a louvered one (air-to-oil if it is what you mean), as the water-to-oil coolers, like Laminova coolers, are very efficient.

http://m.ebay.com/itm/380868637385?_mwBanner=1 This is what its got, i meant i could louver the undearneath hatch cover to let some air out past the sump

Rosco 22nd July 2015 08:36 PM

Well got the rest of the holes drilled last night and debured



I used Wurth Bond and Seal to bond it on, just put a small bead down the middle of all the rails covering all the holes, it was just enough as I was still covered in it!

My mate let me use his air rivet gun! It's a good job as there's no way I would of done it by hand






Rosco 23rd July 2015 07:57 PM

Made myself a rivnut tool tonight



Then fitted the rivnuts round the hatch opening



Then spun her over



I love how the bead rolling has turned out


Rosco 24th July 2015 07:29 AM

Just the right amount of sealant, this is down to my dad as I wanted to put more on but I resisted


norton 25th July 2015 06:20 PM

Hi again, can I ask what size rivets you used to attach you floor please?

norton 25th July 2015 06:28 PM

Hi, what size rivets did you use to attach your floor please?

norton 26th July 2015 07:56 AM

Stupid forum! Sorry I wasn't being impatient. Each time I tried to post a message it told me to get lost and didn't show the message!

Rosco 26th July 2015 08:58 PM

No worries mate, I used 4mm rivets, I felt 4.8mm were a bit large, I spaced them at 45mm apart, looks ok I think, I've used a good quality adhesive to

Rosco 10th August 2015 09:11 AM

This was from last week but the forum was playing up and i forgot to post it

Two full days of updates tonight

Made some stainless spacers from some tube for my pedal box



Then went down my local bolt shop



Pedal box assembled and fitted





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